E92 E93 Repair

2007 BMW 335i
ACCESSORIES AND EQUIPMENT Audio, Navigation and Anti-Theft - Repair Instructions
ACCESSORIES AND EQUIPMENT
Audio, Navigation and Anti-Theft - Repair Instructions
GENERAL INFORMATION
65 00.. OVERVIEW OF AUDIO COMPONENTS (HIFI SYSTEM)
Fig. 1: Overview Of Audio Components (Hifi System)

Courtesy of BMW OF NORTH AMERICA, INC.
65 00.. OVERVIEW OF AUDIO COMPONENTS (TOP HIFI SYSTEM)

2007 BMW 335i
Fig. 2: Overview Of Audio Components (Top Hifi System)

65 00.. OVERVIEW OF AUDIO COMPONENTS (STEREO SYSTEM)

2007 BMW 335i
Fig. 3: Overview Of Audio Components (Stereo System)

MONO RADIO
65 11... INSTRUCTIONS ON SETTING THE INSTALLATION LOCATION ON THE CD CHANGER
NOTE: To ensure trouble-free CD changer operation, ensure both suspension springs

are correctly positioned (horizontal/vertical). If necessary, correct adjustment.
To avoid premature contamination of the CD changer, make sure the magazine

compartment flap is permanently closed.
NOTE: For purposes of clarity, the following graphics show the CD changer removed.
NOTE:  Observe the following repair instructions if the magazine cannot be

removed from the CD changer.
 E36:
Observe Notes on handling CD changers

2007 BMW 335i
 E60, E61, E63, E64:
Remove CD changer magazine
 E83:
Ejection via self-diagnosis
 E87, E90, E91:
CD changer must be sent in
Remove cover cap (1) from CD changer (2).
Fig. 4: Identifying Cover Cap And CD Changer

Arrange installation location of CD changer (2) with a suitable tool by sliding suspension spring (1) into
required position.
Fig. 5: Identifying CD Changer And Suspension Spring

2007 BMW 335i
65 11... REMOVING AND INSTALLING/REPLACING SATELLITE TUNER (US VERSION ONLY)
Necessary preliminary work
 Remove RADIO
NOTE: Satellite tuner can be recognized by the violet aerial connection (1) which is
also located next to the black aerial connection (2).
Additional work is required when the satellite tuner is replaced!
Fig. 6: Identifying Violet Antenna Connection And Black Antenna Connection

Replacement
Record SID number (1) of the removed device.
NOTE: The SID number (1) can be found on the label of the housing.
Record SID number (1) of the new device.
2007 BMW 335i
Fig. 7: Identifying SID Number

Carry out VEHICLE PROGRAMMING/ENCODING .
Please contact Sirius. Use the SID number to cancel current device and register new one.
65 11 070 REMOVING AND INSTALLING/REPLACING CD CHANGER (COUPE)
IMPORTANT: Read and comply with Notes On Protection Against Electrostatic Damage (ESD
Protection) .
Necessary preliminary tasks:
 Disconnect Battery Negative Lead

 Remove Luggage Compartment trim on left.
 If necessary, remove Video Module For On-Board Monitor
NOTE: Follow instructions for Handling Optical Fibres. .
Release screws (1).
Pull CD changer (2) forward and unlock and disconnect plug connections.
Remove CD changer (2) complete with holder.

2007 BMW 335i
Fig. 8: Identifying Screws And CD Changer

Replacement:
Release screws (1) and remove holder (3) from CD changer (2).
Fig. 9: Identifying Screws, Holder And CD Changer

65 11 072 REMOVING AND INSTALLING/REPLACING CD CHANGER (CONVERTIBLE)
Protection) .

 Remove luggage compartment trim on left.
2007 BMW 335i
Release screws (1).
Disconnect plug connections (2).
Remove CD changer (3) complete with holder.
Fig. 10: Identifying Screws, Connector, And CD Changer

Replacement:
Release screws (1) on both sides and remove bracket (2) from CD changer.
Fig. 11: Identifying CD Changer Bracket And Screws

65 11 080 REMOVING AND INSTALLING/REPLACING RADIO RECEIVER
Protection) .
2007 BMW 335i

 Remove Operator Unit For Heater/Air Conditioner
NOTE: Comply with notes and instructions on Handling Optical Waveguides.
Release screws (1).
Pull back radio receiver (2) slightly.
Disconnect associated plug connections and remove radio receiver (2).
Installation:
Make sure the rear guide pin of the radio receiver (2) is correctly seated in the associated mounting.
Fig. 12: Identifying Radio Receiver, Mounting Screws And Removal Direction
For US version only:
If there is a violet antenna connection (1) present in addition to the black antenna connection (2), additional
work is required when replacing the radio receiver!
Refer to Replacing satellite tuner!

2007 BMW 335i
Fig. 13: Identifying Violet Antenna Connection And Black Antenna Connection
Replacement:
Carry out PROGRAMMING/ENCODING
STEREO RADIO, AMPLIFIER

6500... OVERVIEW OF AUDIO COMPONENTS (HIFI SYSTEM)
2007 BMW 335i
Fig. 14: Overview Of Audio Components (HiFi System)

6500... OVERVIEW OF AUDIO COMPONENTS (TOP HIFI SYSTEM)

2007 BMW 335i
Fig. 15: Overview Of Audio Components (Top HiFi System)

6500... OVERVIEW OF AUDIO COMPONENTS (STEREO SYSTEM)

2007 BMW 335i
Fig. 16: Overview Of Audio Components (Stereo System)

65 12 230 REMOVING AND INSTALLING/REPLACING DAB TUNER
Protection) .
NOTE: Follow Instructions For Handling Optical Fibres.
 Disconnect Battery Negative Lead battery negative lead

 Remove Luggage Compartment Floor Trim
E93:
 Remove panel for luggage compartment partition
Release screws (1).

2007 BMW 335i
Disconnect plug connections (2) and remove bracket with DAB tuner (3).
Installation:
DAB tuner bracket (3) must be inserted in guides.
Fig. 17: Identifying Screws, Plug Connections And DAB Tuner

Replacement:
Release screws (1) and remove DAB tuner (2).
Fig. 18: Identifying Screws And DAB Tuner

65 12 050 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT CENTRAL BASS

SPEAKER (UNDER FRONT SEAT)
 Remove Front Seat

2007 BMW 335i
Release screws (1).
Remove central bass speaker trim (2) from floor trim (3).
Fold back floor panel (3) in direction of arrow.
Fig. 19: Identifying Screws, Central Bass Speaker Trim And Floor Trim
Unscrew nuts (1).
Feed out central bass speaker (2) and remove.
Unlock plug connection (3) and disconnect.
Fig. 20: Identifying Nuts, Central Bass Speaker And Plug Connection
Installation:
Make sure seal (3) and rubber damper (4) are correctly seated on central bass speaker (1).
2007 BMW 335i
Insert central bass speaker (1) with guides (2) exactly in frame side member.
Fig. 21: Identifying Seal, Guides, Rubber Damper And Central Bass Speaker
65 12 070 REMOVING AND INSTALLING/REPLACING AMPLIFIER (HIFI SYSTEM) (COUPE)
Protection) .

 Remove Luggage Compartment Trim On Left .
 If necessary, remove Video Module
 If necessary, remove CD Changer
Unfasten plug connection (2) and disconnect.
Release screws (1).
Remove amplifier (3) complete with holder (4).

2007 BMW 335i
Fig. 22: Identifying Screws, Plug Connection, Amplifier And Holder

Replacement:
Release screw (2).
Unscrew nuts (4).
Remove amplifier (1) from holder (3).
Fig. 23: Identifying Amplifier, Screws, Holder And Nuts

65 12 072 REMOVING AND INSTALLING (REPLACING) AMPLIFIER (TOP HI-FI SYSTEM)

(COUPE)
Protection) .
NOTE: Comply with notes and instructions on Handling Optical Waveguides.

2007 BMW 335i

 Vehicles with CD changer or video module only:
 Remove Luggage Compartment trim on left.
 Remove Video Module
 Remove CD Changer
Vehicles without CD changer or video module only:
Unclip cover (1) in direction of arrow from luggage compartment trim panel (2).
Fig. 24: Identifying Cover, Luggage Compartment Trim Panel And Removal Direction
Shown with luggage compartment trim panel removed:
Unlock plug connections (2) and disconnect.
Pull out retaining plates (3) in direction of arrow.
Remove amplifier (1) from holder (4).
Fig. 25: Identifying Retaining Plates, Plug Connection, Holder, Amplifier And Removal Direction
2007 BMW 335i
NOTE: Until 09/2009 a Top HiFi amplifier with a different pin assignment is installed!
Install cable jumper consisting of socket (1) (BMW Parts Service 6901844) and wire jumper (2) in connector
(3).
Create wire jumper (2) from wire (cross-section 0.75 mm) and two stops (BMW Parts Department 1393724).
Then connect pins 1 and 2 in the socket (1) with wire jumper (2).
NOTE: Connector chamber (4) is not included in current version and remains unused
in new replacement Top HiFi amplifier!
Fig. 26: Identifying Wire Jumper, Socket, Connector, And Connector Chamber
Replacement:
65 12 072 REMOVING AND INSTALLING (REPLACING) AMPLIFIER (TOP HI-FI SYSTEM)

(CONVERTIBLE)
Protection) .
Necessary preliminary work:
 Remove Luggage Compartment trim on left side panel.

2007 BMW 335i
Pull out retaining plates (1) in direction of arrow and feed out amplifier towards top. Unfasten plug connection.
Fig. 27: Pulling Out Retaining Plates And Feeding Out Amplifier Towards Top
Installation note:
To prevent rattling, make sure retaining plates (1) are correctly seated in retaining tabs (2).
Fig. 28: Identifying Retaining Plates And Tabs

NOTE: Until 09/2009 a Top HiFi amplifier with a different pin assignment is installed!
Install cable jumper consisting of socket (1) (BMW Parts Service 6901844) and wire jumper (2) in connector
(3).
Create wire jumper (2) from wire (cross-section 0.75 mm) and two stops (BMW Parts Department 1393724).
Then connect pins 1 and 2 in the socket (1) with wire jumper (2).
2007 BMW 335i
NOTE: Connector chamber (4) is not included in current version and remains unused
in new replacement Top HiFi amplifier!
Fig. 29: Identifying Wire Jumper, Socket, Connector, And Connector Chamber
Replacement:
65 12 070 REMOVING AND INSTALLING/REPLACING AMPLIFIER (HIFI SYSTEM, WITH CD

CHANGER) (CONVERTIBLE)
Protection) .

 If necessary, remove CD Changer
Release screws (1).

2007 BMW 335i
Fig. 30: Identifying Screws

Release screw (1).
Fig. 31: Identifying Screw

Release screw (1) and remove complete amplifier (2) with bracket.
2007 BMW 335i
Fig. 32: Identifying Screw And Complete Amplifier With Bracket

Replacement:
Release screws (1) and remove amplifier (2) from bracket.
Fig. 33: Identifying Amplifier And Screws

65 12 200 REMOVING AND INSTALLING (REPLACING) AUDIO SYSTEM CONTROLLER
Protection) .

 Remove Operator Unit For Heater/Air Conditioner (with CCC/ASK)
 Remove Centre Console Switch Cluster (with CCC/ASK)
2007 BMW 335i
NOTE: Comply with notes and instructions on Handling Optical Waveguides. .
Release screws (1).
Pull back audio system controller (2) slightly.
Unlock associated plug connections and disconnect.
Remove audio system controller (2).
Fig. 34: Identifying Screws, Audio System Controller And Removal Direction
Replacement:
65 12 220 REMOVING AND INSTALLING/REPLACING SATELLITE TUNER (ONLY FOR US

MODELS STARTING AT 09/2009)
 Remove CAR INFOTAINMENT COMPUTER
Record SID number (1) of the removed device.
NOTE: The SID number (1) can be found on the label of the housing. Location may be
different, depending on the equipment manufacturer.
2007 BMW 335i
Fig. 35: Identifying SID Number

Record SID number (1) of the new device.
Input enabling code from the Aftersales Assistance Portal, ASAP.
Replacement:
Perform PROGRAMMING/ENCODING .
NOTE: Please contact Sirius. Use the SID number to cancel current device and register
new one.
65 12 220 REMOVING AND INSTALLING/REPLACING SATELLITE RADIO (ONLY FOR US

MODELS STARTING AT 09/2009)
IMPORTANT: Read and comply with notes on Notes On Protection Against Electrostatic
Damage (ESD Protection) .
NOTE: Follow instructions for handling optical fibres. .
 Disconnect negative battery cable .

 Remove luggage compartment floor panel .
Disconnect plug connection (1).
Release screws (2) and feed out satellite tuner (3).

2007 BMW 335i
Installation:
 Unlock plug connections correctly.

 Bracket (4) must be inserted in guides on floor pan.
Fig. 36: Removing Satellite Tuner, Bracket And Screws

Replacement:
Release screws (1) and remove bracket (2) from satellite tuner (3).
Fig. 37: Remove Bracket From Satellite Tuner

When replacing, please observe:
Record ID number (2) of the removed device.
NOTE: The ID number (2) can be found on the label of the housing. Above the barcode
2007 BMW 335i
the text reads "Sirius ID" (1) and next to it is the company's logo "Sirius
Satellite Radio" (3).
Record ID number (2) of the new device.
Fig. 38: Identifying Sirius Logo, ID Number, And "Sirius ID" Text Above Barcode
Replacement:
Carry out vehicle programming/encoding .
NOTE: Please contact Sirius. Use the ID number to cancel current device and register
new one.
65 12 230 REMOVING AND INSTALLING/REPLACING DAB TUNER
Protection) .

 Remove luggage compartment floor trim
E93:
2007 BMW 335i
 Remove panel for luggage compartment partition
Release screws (1).
Disconnect plug connections (2) and remove bracket with DAB tuner (3).
Installation:
DAB tuner bracket (3) must be inserted in guides.
Fig. 39: Identifying Screws, Plug Connections And Bracket With DAB Tuner
Replacement:
Release screws (1) and remove DAB tuner (2).
Fig. 40: Identifying Screws And DAB Tuner

SPEAKER AND COVER

2007 BMW 335i
65 13 050 REMOVING AND INSTALLING/REPLACING SPEAKER (TWEETER IN

QUARTERLIGHT MIRROR)
 Remove Front Door Trim Panel

 Remove Quarterlight Mirror
Remove sound insulation (1).
Fig. 41: Identifying Sound Insulation

Unclip speaker (1) from mountings (2) and remove.
Installation:
Retaining lugs (2) must not be damaged
Fig. 42: Identifying Speaker And Mountings

65 13 060 REMOVING AND INSTALLING/REPLACING SPEAKER (MID-RANGE SPEAKER, IN

INSTRUMENT PANEL)
2007 BMW 335i
Unclip trim for speaker cover (1) at fastening points (2) and (3) and remove
Fig. 43: Identifying Speaker Cover And Fastening Points

Release screws (1).
Remove speaker (2).
Disconnect associated plug connection and remove speaker (2) towards top.
Fig. 44: Identifying Screws And Speaker

65 13 070 REMOVING AND INSTALLING/REPLACING SPEAKER (MID-RANGE SPEAKER IN

DOOR TRIM PANEL AT FRONT)
 Remove Front Door Trim
NOTE: Secure speaker against falling out.
Release nuts (1) and remove speaker (2) in direction of arrow from door trim (3).
2007 BMW 335i
For tightening torque refer to 65 13 1AZ in 65 13 SPEAKERS .
NOTE: The studs for the speaker screw connection are microencapsulated.
Fig. 45: Identifying Door Trim, Nuts And Speaker

Build date E90 / E91 from CW 44/2005:
NOTE: A. Previous version with adapter lead and external capacitor

B. New version with integrated capacitor
Adapter lead with capacitor on speaker omitted.
Remove adapter lead completely in each case when replacing.
Fig. 46: Identifying Speaker With External Capacitor And Integrated Capacitor Versions (E90 / E91)
Build date E87 from CW 44/2005:

2007 BMW 335i
NOTE: A. Previous version with adapter lead and external capacitor

B. New version with integrated capacitor
Adapter lead with capacitor on speaker omitted.
Remove adapter lead completely in each case when replacing.
Fig. 47: Identifying Speaker With External Capacitor And Integrated Capacitor Versions (E87)
65 13 080 REMOVING AND INSTALLING/REPLACING SPEAKER (TWEETER IN REAR SIDE

TRIM PANEL)
 Remove Rear Side Trim Panel
Release plastic nut (2) in counterclockwise direction and feed out speaker (3) towards front.
Installation:
Do not place plastic nut (2) on thread at a skewed angle.

2007 BMW 335i
Fig. 48: Identifying Plug Connection, Plastic Nut And Speaker

65 13 090 REMOVING AND INSTALLING/REPLACING SPEAKER (MID-RANGE SPEAKER,

REAR SIDE TRIM PANEL)
Release screws (1).
Remove speaker (2) upwards from side trim panel.
For tightening torque refer to 65 13 1AZ in 65 13 SPEAKERS .
Fig. 49: Identifying Screws And Speaker

65 13 188 REMOVING AND INSTALLING/REPLACING REAR MID-RANGE SPEAKER (IN REAR

SHELF)
2007 BMW 335i
Special tools required:
 00 9 341
Lever speaker cover (1) with special tool 00 9 341 out of rear shelf (2).
Fig. 50: Identifying Speaker Cover, Special Tool (00 9 341, Rear Shelf And Removal Direction
Installation:
Lugs (1) and locks (2) of speaker cover (3) must not be damaged.
Fig. 51: Identifying Lugs, Looks And Speaker Cover

Release screws (1).
Remove mid-range speaker (2) upwards from rear shelf (3).
Disconnect associated plug connections and remove mid-range speaker (2).

2007 BMW 335i
Fig. 52: Identifying Screws, Mid-Range Speaker And Rear Shelf

65 13 400 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT FREQUENCY GATE
Necessary preliminary tasks
 Remove FRONT DOOR TRIM PANEL
Release screws (2) and remove frequency gate.
Fig. 53: Identifying Plug Connection And Frequency Gate Screws

AERIAL/ANTENNA
65 20 030 REMOVING AND INSTALLING/REPLACING EMPTY HOUSING FOR ROOF-
MOUNTED AERIAL/ANTENNA

2007 BMW 335i
 65 2 010
NOTE: Clean roof.
Tape off roof surface (2) around aerial/antenna cover (3) with yellow adhesive tape (1). To do so, slide adhesive
tape slightly under roof aerial/antenna.
If necessary, carefully heat vehicle roof in aerial/antenna area with a hot air blower (max. 50°C).
Fig. 54: Identifying Adhesive Tape, Roof Surface And Aerial/Antenna Cover
IMPORTANT: Risk of damage!
Handle special tool correctly and make sure you are standing safely with a firm
foothold next to vehicle.
In order to prevent dents in the roof outer skin, do not exert any pressure on
the roof.
Make sure your arms do not cross over (1) when holding special tool 65 2 010.
Pull handle must always be ahead of the guiding hand (2).

2007 BMW 335i
Fig. 55: Identifying Correct Use Of Special Tool (65 2 010)

Cut through adhesive bead all round with special tool 65 2 010.
Pull on handle (1) and align blade on handle (2).
NOTE: Use sharp blades only. If necessary, sharpen blades.
Remove cover of multiband telephone antenna (3).
Fig. 56: Identifying Multiband Telephone Antenna Cover, Handle And Blade Of Special Tool (65 2 010)
Installation
The cover of the multiband telephone aerial/antenna is secured with window adhesive. All preparatory
operations correspond to the Window Cementing Instructions .
2007 BMW 335i
NOTE: The aerial/antenna cover must be replaced if its centering pins (1) are damaged.
Bonding surface (2) must be clean and free from grease.
Fig. 57: Identifying Centering Pins And Surface

Position two spacers (1) on cleaned aerial/antenna cover.
Dimensions:
A. 10 mm
B. 14 mm
Position spacer (2) centrally and flush with shoulder of adhesive flange.
IMPORTANT: Spacers must be used without fail!
Fig. 58: Identifying Spacers And Dimensions On Aerial/Antenna Cover

2007 BMW 335i
Apply trace of adhesive bead all round outer contour as follows.
Distance between adhesive bead and edge of aerial/antenna cover:
A. 6.5 mm ± 1 mm
Start and end of bead trace must have an overlap length of max. 10 mm.
IMPORTANT: To prevent the adhesive from escaping, the adhesive bead diameter must not
exceed 3 mm ± 1 mm.
Fig. 59: Identifying Distance Between Adhesive Bead And Edge Of Aerial/Antenna Cover
NOTE: Attach the antenna cover coated with adhesive by hand. To spread the adhesive
better, move the cover back and forth horizontally slightly when pressing down.
If necessary, secure antenna cover with adhesive tape and do not press down
on one side of the antenna more firmly than the other.
After bonding, leave vehicle to stand for at least 3 hours at room temperature.
To guarantee a permanent bond:
Only use washing installations after a period of 24 hours has passed.
65 20 035 REMOVING AND INSTALLING/REPLACING ROOF-MOUNTED AERIAL/ANTENNA
 Detach Empty Housing for roof-mounted aerial/antenna

2007 BMW 335i
Release screw (1) and feed out roof aerial/antenna (2) towards top.
Fig. 60: Identifying Screw And Roof Aerial/Antenna

Disconnect plug connections (1) and remove aerial/antenna (2).
Installation:
Do not mix up aerial/antenna connections (1).
Fig. 61: Identifying Plug Connections And Aerial/Antenna

65 20 090 REMOVING AND INSTALLING OR REPLACING AERIAL AMPLIFIER (COUPE)
 Remove luggage compartment trim on side panel
Release screws (1).

2007 BMW 335i
Remove aerial amplifier (3).
Fig. 62: Identifying Screws, Plug Connections And Aerial Amplifier

65 20 090 REMOVING AND INSTALLING OR REPLACING AERIAL AMPLIFIER

(CONVERTIBLE)
 Remove luggage compartment trim on side panel .
Release screw (1).
Disconnect plug connections (2) and remove antenna amplifier.
Fig. 63: Disconnect Plug Connections (2) And Remove Antenna Amplifier
2007 BMW 335i
65 20 130 REMOVING AND INSTALLING/REPLACING LEFT ANTENNA AMPLIFIER

(CONVERTIBLE)
 Remove upper section of side trim panel .
Disconnect plug connections (1) and feed out cable.
Release screw (2).
Remove antenna amplifier (3).
Fig. 64: Disconnect Plug Connections (1) And Feed Out Cable
65 20 132 REMOVING AND INSTALLING/REPLACING RIGHT ANTENNA AMPLIFIER

(CONVERTIBLE)
Operation is identical to: Removing and installing/replacing left antenna amplifier.
65 20 140 REMOVING AND INSTALLING/REPLACING LEFT ANTENNA (AM/FM)

(CONVERTIBLE)
 Remove upper section of side trim panel .
Release retaining rings (1) and remove sound insulation (2).

2007 BMW 335i
Fig. 65: Release Retaining Rings (1) And Remove Sound Insulation (2).
IMPORTANT: Antenna (1) must not be kinked.
Remove antenna (1).
Fig. 66: Remove Antenna (1)

65 20 142 REMOVING AND INSTALLING/REPLACING RIGHT ANTENNA (AM/FM)

(CONVERTIBLE)
Operation is identical to: Removing and installing/replacing left antenna.
65 20 150 REMOVING AND INSTALLING/REPLACING BACKUP ANTENNA (COUPE)
 Remove Panel For Parcel Shelf

2007 BMW 335i
Unscrew nuts (2).
Remove back-up antenna (3) from rear window shelf (4).
Fig. 67: Identifying Back-Up Antenna, Rear Window Shelf, Plug Connection, Nuts And Removal
Direction
65 20 150 REMOVING AND INSTALLING/REPLACING BACKUP ANTENNA (CONVERTIBLE)
 Remove lower section of side trim .
For purposes of clarity, the lowerable hardtop is shown opened in the following work steps.
Remove sound insulation (1).
Installation:
Make sure sound insulation (1) is correctly seated.

2007 BMW 335i

Remove screws (2) and remove back-up antenna.
Fig. 69: Identifying Connector And Screws

65 20 160 REMOVING AND INSTALLING/REPLACING TV AERIAL (CONVERTIBLE)
 Remove luggage compartment trim on left side panel

 Remove rear bumper trim
NOTE: The operation is described on the left side; proceed in the same way for the
right side.
2007 BMW 335i
Release screw (1) and remove antenna.
Unclip antenna lead (2) on both sides completely.
Installation:
Ensure correct lead routing.
Fig. 70: Identifying Antenna Lead And Screw

65 20 220 REMOVING AND INSTALLING/REPLACING REAR WINDOW ANTENNA AMPLIFIER

(CONVERTIBLE)
Move lowerable hardtop into position shown.
Fig. 71: Move Lowerable Hardtop Into Position

Release screw (1) and disconnect plug connections (2).

2007 BMW 335i
Fig. 72: Release Screw (1) And Disconnect Plug Connections (2)
65 20 240 REMOVING AND INSTALLING/REPLACING TELEPHONE ANTENNA

(CONVERTIBLE)
 Remove front wheel arch trim
Release nut (2), turn telephone antenna (3) and feed out.
Fig. 73: Release Nut (2), Turn Telephone Antenna (3) And Feed Out
65 20 250 REMOVING AND INSTALLING/REPLACING REAR TELEPHONE ANTENNA

(CONVERTIBLE)

2007 BMW 335i
 Remove rear bumper trim

 Remove luggage compartment trim on left side panel
NOTE: For purposes of clarity, the bumper bracket is shown removed.
Release screw (1).
Turn telephone antenna (2) and feed out.
Feed out lead (3) and disconnect associated plug connection.
Installation:
Make sure grommet is correctly seated so as to avoid water ingress.
Fig. 74: Feed Out Lead (3) And Disconnect Associated Plug Connection
65 20 300 REMOVING AND INSTALLING/REPLACING BUMPER ANTENNA (CONVERTIBLE)
 Remove luggage compartment trim on left .

 Remove rear bumper trim .
Unclip cable fasteners (1).

2007 BMW 335i
Fig. 75: Unclip Cable Fasteners (1)

Pull out grommet (1).
Installation:
Make sure grommet (1) is correctly seated so as to avoid water ingress.
Fig. 76: Make Sure Grommet (1) Is Correctly Seated So As To Avoid Water Ingress
Disconnect plug connection (1) and feed out antenna lead.

2007 BMW 335i
Fig. 77: Disconnect Plug Connection (1) And Feed Out Antenna Lead
65 20 350 REMOVING AND INSTALLING/REPLACING SUPPRESSION FILTER
Release screw (2).
Remove suppression filter (3) from C-pillar.
Fig. 78: Identifying Plug Connection, Screw And Suppression Filter

Installation:
Fit suppression filter (1) so that screw (2) engages thread (3) and locating pin (4) engages bore (5).
2007 BMW 335i
Fig. 79: Identifying Suppression Filter, Bore, Screw, Thread And Locating Pin
65 20 780 REMOVING AND INSTALLING/REPLACING AERIAL OF GLOBAL POSITIONING

SYSTEM (GPS) (CONVERTIBLE)
Damage (ESD Protection) .
 Remove roof switch cluster .
Unclip cable holder (2) from aerial holder for Global Positioning System (3).
Release screws (4). Remove aerial of Global Positioning System (3) from cowl panel (5).
Fig. 80: Removing Aerial Of Global Positioning System (3) From Cowl Panel (5)
2007 BMW 335i
REAR WINDOW AERIAL/ANTENNA

65 24 020 REMOVING AND INSTALLING OR REPLACING BLOCKING CIRCUIT (COUPE)

 If necessary, lay rear window shelf sound insulation to one side
Release screw (2).
Remove blocking circuit (3) from C-pillar.
Fig. 81: Identifying Plug Connections, Screws And Blocking Circuit

Installation:
Fit blocking circuit (1) so that screw (2) engages thread (3) and locating pin (4) engages bore (5).
2007 BMW 335i
Fig. 82: Identifying Blocking Circuit, Screw, Thread, Bore And Locating Pin
65 24 020 REMOVING AND INSTALLING/REPLACING BLOCKING CIRCUIT (LEFT OR RIGHT)

(CONVERTIBLE)
Move lowerable hardtop into position shown.
Fig. 83: Move Lowerable Hardtop Into Position Shown

Release screw (1) and disconnect plug connections (2).
Fig. 84: Release Screw (1) And Disconnect Plug Connections (2)
Installation:
Fit blocking circuit (1) so that screw (2) engages thread (3) and locating pin (4) engages bore (5).
2007 BMW 335i
Fig. 85: Fit Blocking Circuit (1) So Screw (2) Engages Thread (3) And Locating Pin (4) Engages Bore (5)
VIDEO AND TV EQUIPMENT

65 50 011 REMOVING AND INSTALLING (REPLACING) VIDEO MODULE FOR ON-BOARD
MONITOR (COUPE)
Protection) .
 Disconnect Battery Negative Lead .

Unfasten screws (2) and nuts (3).
Pull back video module for on-board monitor (1) and disconnect plug connections.
Remove video module for on-board monitor (1) complete with holder.
2007 BMW 335i
Fig. 86: Identifying On-Board Monitor, Screws And Nuts

Replacement:
Release screws (3) and remove holder (2) from video module for on-board monitor (1).
Fig. 87: Identifying On-Board Monitor, Holder And Screws

Replacement:
65 50 011 REMOVING AND INSTALLING (REPLACING) VIDEO MODULE FOR ON-BOARD

MONITOR (CONVERTIBLE)
Protection) .
 Disconnect battery negative lead .

2007 BMW 335i
 Remove luggage compartment floor panel .
NOTE: Follow instructions for handling optical fibres .
Release screws (1).
Disconnect plug connections (2) and remove bracket (3) with video module.
Fig. 88: Identifying Connectors, Screws, And Bracket

Installation:
Ensure correct cable routing.
Replacement:
Release screws (1) on both sides and remove video module (2) from bracket.
Carry out programming/coding .

2007 BMW 335i
Fig. 89: Identifying Video Module And Screws

ANTI-THEFT ALARM SYSTEM

65 75 055 REMOVING AND INSTALLING/REPLACING EMERGENCY POWER SIREN WITH
TILT SENSOR
 Remove Rear Left Wheel Arch Cover
Release screws (1) and lower complete mounting plate (2).
Unlock and disconnect associated plug connection, remove complete mounting plate (2).
Fig. 90: Identifying Screws And Mounting Plate

Release nut (1) and remove emergency power siren with tilt sensor (2) from mounting plate (3).
2007 BMW 335i
Fig. 91: Identifying Nut, Sensor And Mounting Plate

65 75 071 REMOVING AND INSTALLING (REPLACING) MODULE FOR INTERIOR MOVEMENT

DETECTOR (COUPE)
Protection) .
 Remove Complete Ceiling Light (Rear)
Open retaining hooks (1) and feed module for passenger compartment sensor (2) in direction of arrow out of
trim (3) and remove.
Installation:
Retaining hooks (1) must not be damaged.
Fig. 92: Identifying Module For Passenger Compartment Sensor, Trim, Hooks And Removal Direction
Replacement:
2007 BMW 335i
65 75 080 REMOVING AND INSTALLING/REPLACING INTERIOR MOVEMENT DETECTION

MODULE IN LEFT OR RIGHT FRONT DOOR (CONVERTIBLE)
 Remove Front Door Trim
Release bolt (1) and feed out interior movement detection module (2).
Fig. 93: Identifying Interior Movement Detection Module And Bolt

Replacement:
Carry out PROGRAMMING/CODING
65 75 090 REMOVING AND INSTALLING/REPLACING INTERIOR MOVEMENT DETECTION

MODULE IN LEFT OR RIGHT B-PILLAR (CONVERTIBLE)
IMPORTANT: Read and comply with notes on Protection Against Electrostatic Damage (ESD
Protection) .
Remove lower section of side trim
Release screw (1). Detach interior movement detection module (2) in direction of arrow from side trim.
2007 BMW 335i
Fig. 94: Detach Interior Movement Detection Module

Replacement:
Carry out PROGRAMMING/CODING
AIRBAG TRIGGER UNIT, DIAGNOSTICS

65 77... NOTES ON SCRAPPING BMW VEHICLES WITH GAS GENERATORS (CENTRAL
AIRBAG CONTROL UNIT, AIRBAG SYSTEM)
The gas generator is a pyrotechnic component of:
 Airbag module
 Driver's/passenger airbag
 Side airbags
 Head airbag
 Knee airbag
 Belt pretensioner
 Belt buckle tensioner
 Safety battery terminal
1 Series: E81, E87
3 Series: E46, E90, E91, E92, E93
5 Series: E60, E61 from build date 09/2005
6 Series: E63, E64 from build date 09/2005
X3: E83
2007 BMW 335i
X5: E53, E70
Z4: E85, E86
Gas generators that have not fired constitute a hazard (also to the environment)!
In accordance with accident prevention regulations and specific national regulations, gas generators must be
rendered unusable before they are scrapped. This is necessary because pyrotechnical objects can cause injury if
improperly activated (e.g. scrapping with flame cutters).
With above-mentioned vehicles which are scheduled for scrapping, it is always essential prior to draining and
further stripping work to ensure that all the gas generators in the vehicle are fired. The fired gas generators can
then be scrapped together with the vehicle.
Triggering failure
If correct triggering is not possible, the relevant components must (while observing the safety regulations for
handling airbag system components) be removed and disposed of by special disposal companies!
If a triggering operation has failed:
 Disconnect the triggering device from the battery and

 only approach the vehicle after a few minutes have elapsed
The components of an airbag system must always be disposed of. Such components must not be sold on as
used parts.
Triggering
Triggering of the gas generators may only be carried out by expert personnel and under the supervision of a
responsible person. Other standard accident prevention regulations (safety goggles, ear defenders etc.) must also
be observed.
The gas generators must be fired from the outside in the vehicle scheduled for scrapping with the doors closed
but with the tailgate, door windows and sunroof open. To fire the gas generators, use the BMW-developed
triggering device with the corresponding cables.
WARNING: Once gas generators have been fired, observe a ventilation period of 10
minutes with the doors opened. Only then is it permitted to continue work
inside the vehicle.
Wear protective goggles and protective gloves when handling a fired gas
generator!
The burning of solid fuel will heat up airbag unit - danger of burning
hands!
2007 BMW 335i
Wash skin with water after contact with fired gas generators!
1. Vehicles with central airbag control unit (all airbags, seat belt pretensioners, safety battery
terminal)
1. Expose airbag control unit.
2. Connect "Airbagmaster".
72 12... OVERVIEW OF AIRBAG MODULES, AIRBAG CONTROL UNIT, BELT TENSIONERS

(COUPE)
Fig. 95: Overview Of Airbag Modules, Airbag Control Unit, Belt Tensioners (Coupe)
72 12... OVERVIEW OF AIRBAG MODULES, AIRBAG CONTROL UNIT, BELT TENSIONERS

(CONVERTIBLE)
2007 BMW 335i
Fig. 96: Overview Of Airbag Modules, Airbag Control Unit, Belt Tensioners (Convertible)
65 77... OVERVIEW OF SENSORS FOR AIRBAG SYSTEM (COUPE)

2007 BMW 335i
Fig. 97: Overview Of Sensors For Airbag System

65 77... OVERVIEW OF SENSORS FOR AIRBAG SYSTEM (CONVERTIBLE)

2007 BMW 335i
Fig. 98: Overview Of Sensors For Airbag System (Convertible)

65 77 016 REMOVING AND INSTALLING/REPLACING AIRBAG CONTROL UNIT
Protection) .
WARNING: Note Airbag Safety Instructions !
Incorrect handling can activate airbag and cause injury.
 Disconnect Battery Negative Lead and cover

2007 BMW 335i
 Remove Storage Compartment
If necessary, remove foam cover from airbag control unit.
Release screw (2) and nuts (3).
For tightening torque refer to 65 77 1AZ in 65 77 AIRBAG TRIGGERING CONTROL .
Installation:
Before screwing down airbag control unit (4), make sure negative lead (5) is resting on associated threaded pin.
Remove airbag control unit (4) in direction of arrow.
Fig. 99: Identifying Airbag Control Unit, Negative Lead, Plug Connection, Screw, Nuts And Removal
Direction
Replacement:
65 77 541 REMOVING AND INSTALLING/REPLACING FRONT LEFT OR RIGHT

ACCELERATION SENSOR
NOTE: Acceleration sensor only fitted in US version!
 Remove front Wheel Arch Trim

2007 BMW 335i
Release screws (2) and remove sensor (3).
Installation:
Replace screws.
Fig. 100: Identifying Plug Connection, Screws And Sensor

65 77 600 REPLACING SENSOR MAT FOR FRONT PASSENGER SEAT OCCUPANCY DETECTOR
Front passenger seat US/CDN version (with OC3 mat) only:
New seat cover must be completely installed with padding, seat heating and OC3 mat.
Release seat occupancy detector:
 Connect diagnosis system

 Release seat occupancy detector
 Clear fault memory if necessary
 Remove Seat Cover For Right Front seat

2007 BMW 335i
Fig. 101: Identifying Front Passenger Seat Sensor Mat Plug Connection
Cut front sticking surface in area on sensor mat (1) with cutter knife or razor blade from foam without
damaging the foam.
Remove sensor mat (1) and feed out electric lead.
Installation:
In order to guarantee the function and fastening (adhesive strength) at the sticking surfaces of sensor mat (1),
the foam most not show any traces of damage at all!
Replace the foam if it is hardened or damaged particularly in the area of the sticking surfaces.
Align new sensor mat (1) to upholstered seat section.
First guide cable through upholstered seat section in area (2).
Secure sensor mat in area (3) and align again.
Pull off adhesive strips in area (4) and stick to upholstered seat section.
Fig. 102: Identifying Sensor Mat, Upholstered Seat Section Area And Adhesive Strips Area
2007 BMW 335i
65 77 601 REPLACING SENSOR MAT FOR FRONT PASSENGER SEAT OCCUPANCY DETECTOR
(SPORT SEAT)
Operation is described in:
Replacing sensor mat for front passenger seat occupancy detector.
65 77 604 REPLACING SENSOR MAT (OC3 MAT) FOR PASSENGER SEAT OCCUPANCY
DETECTOR
See REPLACING SENSOR MAT (OC3 MAT) FOR PASSENGER SEAT OCCUPANCY DETECTOR .
65 77 720 REMOVING AND INSTALLING (REPLACING) LEFT B-PILLAR SENSOR
Protection) .
 Disconnect Battery Negative Lead and cover

Release screw (2) and disconnect plug connection (2).
Fig. 103: Identifying Screw And Plug Connection

2007 BMW 335i
Installation:
Establish correct positioning of B-pillar sensor (1) by means of guide pin (2) and screw (3).
Fig. 104: Identifying Sensor, Guide Pin And Screw

65 77 725 REMOVING AND INSTALLING/REPLACING RIGHT B-PILLAR SENSOR
Operation is identical to:
Removing And Installing Left B-Pillar Sensor
65 77 740 REMOVING AND INSTALLING (REPLACING) LEFT FRONT DOOR SENSOR
Protection) .

 Detach sound insulation in work area
Release screw (2).
Remove sensor with pin (3) from door panel fit (4) towards rear.
Installation:
2007 BMW 335i
Make sure fit (3) is correctly seated.
Fig. 105: Identifying Plug Connection, Screws, Pin And Door Panel
65 77 745 REMOVING AND INSTALLING/REPLACING RIGHT FRONT DOOR SENSOR
This operation is described in:
Removing And Installing (Replacing) Left Front Door Sensor
65 77 770 REMOVING AND INSTALLING (REPLACING) ROLLOVER CONTROLLER
Important! Read and comply with notes on protection against electrostatic damage (ESD protection).
Necessary preliminary tasks: Remove panel for passenger compartment partition .
Release expansion rivets (1). Fold back insulating mat (2).
Fig. 106: Release Expansion Rivets And Fold Back Insulating Mat
2007 BMW 335i
Disconnect plug connection (1). Release screws (2). Remove rollover controller.
Fig. 107: Disconnect Plug Connection (1), Release Screws (2) And Remove Rollover Controller
Function check with BMW diagnosis system: Trigger/retract rollover protection system.
ON-BOARD COMPUTER
65 81 060 REMOVING AND INSTALLING/REPLACING OUTSIDE TEMPERATURE SENSOR
 Remove Front Bumper Trim

 E90, E91, E92, E93 only:
Partially remove Cooling Air Duct At Top left
Snap out outside temperature sensor in direction of arrow and remove.
Installation:
Outside temperature sensor must audibly snap into place.
Check for secure seating after fitting.

2007 BMW 335i
Fig. 108: Identifying Plug Connection And Removal Direction

CENTRAL DISPLAY
65 82 050 REMOVING AND INSTALLING (REPLACING) ON-BOARD MONITOR
Protection) .
IMPORTANT: Proceed with care so as to avoid damaging the on-board monitor and adjoining
trims.
Release screws (1).
Fold out on-board monitor (2) in direction of arrow.
Fig. 109: Identifying On-Board Monitor, Screws And Removal Direction


2007 BMW 335i
Installation:
Remove on-board monitor (2).
Fig. 110: Identifying Plug Connections And On-Board Monitor

Replacement:
6582... REPLACING FRONT TRIM PANEL OF CENTRAL INFORMATION DISPLAY (CID),

(09/2009 ON)
NOTE: Front trim panel can only be replaced on versions without glass cover from
09/2009 on.
 Remove CENTRAL INFORMATION DISPLAY
Release screws (1) and remove front trim panel (2).

2007 BMW 335i
Fig. 111: Identifying Screws And Front Trim Panel

CAR COMMUNICATION COMPUTER

65 83 010 REMOVING AND INSTALLING/REPLACING CAR COMMUNICATION COMPUTER
(CCC)
Protection) .

 Remove Center Console Switch Center
NOTE: Comply with notes and instructions on Handling Optical Waveguides. .
Release screws (1).
Pull back Car Communication Computer (2) slightly.
Remove Car Communication Computer (2).

2007 BMW 335i
Fig. 112: Identifying Removal Direction, Screws And Car Communication Computer
Replacement:
65 83 020 REMOVING AND INSTALLING (REPLACING) CAR INFORMATION COMPUTER (CIC)
A hard disk is installed in the Car Information Computer (CIC).
Carry out mechanical work on the CIC and adjacent components with care.
Avoid subjecting the CIC to vibration/shocks.
IMPORTANT: Read and comply with notes on protection against electrostatic damage (ESD
PROTECTION) .
 Disconnect BATTERY EARTH LEAD

 Remove CENTER CONSOLE SWITCH CLUSTER
NOTE: Comply with notes and instructions on HANDLING OPTICAL FIBRES .
Release screws (1).
Pull back Car Infotainment Computer (2) slightly.

2007 BMW 335i
Remove Car Infotainment Computer (2).
Fig. 113: Removing Car Infotainment Computer

Only for US models with satellite tuner:
When replacing the CIC unit, additional work is required!
 See REPLACE SATELLITE TUNER FROM 09/2009.
Replacement:
Carry out PROGRAMMING/ENCODING .
65 83 550 REMOVING AND INSTALLING/REPLACING FAN FOR CAR COMMUNICATION

COMPUTER
Protection) .
 Remove Car Communication Computer
Raise retaining hook (1) and turn fan for Car Communication Computer (2) in direction of arrow.
Remove fan for Car Communication Computer (2) from Car Communication Computer (3).
2007 BMW 335i
Fig. 114: Identifying Retaining Hook, Car Communication Computer And Removal Direction
65 83 560 REMOVING AND INSTALLING/REPLACING FRONT TRIM FOR CAR

COMMUNICATION COMPUTER
Protection) .
Release screws (1).
Fold down front panel for Car Communication Computer (2) and set down.
Installation:
Make sure retaining lugs (3) of front panel for Car Communication Computer (2) are correctly seated.
Fig. 115: Identifying Car Communication Computer, Screws, Retaining Lug And Removal Direction
2007 BMW 335i
NOTE: "LIF" stands for Low Insertion Force.
Open catch of LIF plug (2) in direction of arrow and feed out LIF cable (1).
Remove front trim for Car Communication Computer (4) from Car Communication Computer (3).
Fig. 116: Identifying Catch Of LIF Plug, LIF Cable Car Communication Computer And Removal
Direction
65 83 570 REMOVING AND INSTALLING/REPLACING CD DRIVE FOR CAR COMMUNICATION

COMPUTER
 64 1 020
Protection) !
 Remove Front Trim For Car Communication Computer
If necessary, cut through warranty seal.
Raise cover (1) with special tool 64 1 020 all round and remove from Car Communication Computer (2).
2007 BMW 335i
Fig. 117: Identifying Car Communication Computer, Cover, Removal Direction And Special Tool (64 1
020)
Release bolts (1).
Feed CD drive for Car Communication Computer (2) in direction of arrow out of Car Communication
Computer (3) and set down.
Installation:
Ensure correct routing of cables.
Fig. 118: Identifying Car Communication Computer, Cover And Removal Direction
Release bolts (1).
Remove CD drive trim (2) in direction of arrow from CD drive for Car Communication Computer (3).
Installation:
2007 BMW 335i
Fig. 119: Identifying CD Drive Trim, Car Communication Computer, Bolts And Removal Direction
Cut through warranty seal (1) at marked point.
Release screw (2).
Lift side cover out of mounting (3) and carefully place to one side.
Fig. 120: Identifying Seal, Screws And Mounting

Disconnect plug connection (1) and remove CD drive.
Installation:

2007 BMW 335i
Fig. 121: Identifying Plug Connection

65 83 580 REMOVING AND INSTALLING/REPLACING DVD DRIVE FOR CAR

 00 9 450
 12 7 192
 64 1 020
Protection) .
Risk of damage!
Place Car Communication Computer on special tool 12 7 192 (antistatic mat)

and earth/ground.
 Remove Front Trim For Car Communication Computer
Raise cover (1) with special tool 64 1 020 all round and remove from Car Communication Computer (2).
2007 BMW 335i
Fig. 122: Identifying Special Tool (64 1 020), Cover And Car Communication Computer
Release bolts (1).
Feed out bridge (2).
Installation:
Use special tool 00 9 450 to tighten down screws.
For tightening torque refer to 65 52 3AZ in 65 52 CD/DVD DRIVES AND SPECIAL DEVICES .
Fig. 123: Identifying Bolts And Bridge

Cut through stickers at marked points (1).
Release screws (2) and remove trim (3).
Installation:
2007 BMW 335i
Use special tool 00 9 450 to tighten down screws.
For tightening torque refer to 65 52 3AZ in 65 52 CD/DVD DRIVES AND SPECIAL DEVICES ..
Fig. 124: Identifying Marked Points, Screws And Trim

Release screws (1) with magnetic screwdriver.
Installation:
Lug (2) of DVD drive must be above lug (3) of Car Communication Computer.
Fig. 125: Identifying Screws And Lug

Turn Car Communication Computer through 180° and carefully feed out DVD drive.
Carefully disconnect plug connections (1, 2).
Remove DVD drive (3).

2007 BMW 335i
Installation:
Fig. 126: Identifying Plug Connections And DVD Drive

NOTE: There are two versions of the plug connection (2) shown in Fig. 126:
Previous version: ribbon cable is connected horizontally (see 1 in Fig. 127)
Current version: ribbon cable is connected vertically (see 2 in Fig. 127)
Fig. 127: Identifying Ribbon Cable Connection Horizontally And Vertically

After installation:
On cars before March 2006 it is essential after replacing the DVD drive to carry out a measures plan or a
2007 BMW 335i
software update as per PROGRAMMING/ENCODING
65 83 590 REMOVING AND INSTALLING/REPLACING GYRO SENSOR DRIVE FOR CAR

Protection) .
Release bolts (1).
Remove floor pan (2) towards bottom and set down.
IMPORTANT: Contact spring strip (3) on floor pan (2) must not be bent: otherwise risk of
short-circuiting!
When reinstalling floor pan (2), make sure individual springs of contact spring
strip (3) are correctly seated.
Fig. 128: Identifying Bolts, Floor Pan And Spring Strip

Release bolt (1).
Detach gyro sensor for Car Communication Computer (2) in direction of arrow from plug-in contact (3).
2007 BMW 335i
Fig. 129: Identifying Bolt, Gyro Sensor, Plug-In Contact And Removal Direction
65 83 600 REPLACING HIP MODULE FOR CAR COMMUNICATION COMPUTER
Protection) .
Release screws (1).
Remove cover (2) towards top.
IMPORTANT: Contact spring strip (3) on floor pan (2) must not be bent: otherwise risk of
short-circuiting!
When reinstalling floor pan (2), make sure individual springs of contact spring
strip (3) are correctly seated.
2007 BMW 335i
Fig. 130: Identifying Bolts, Floor Pan And Spring Strip

Press catches (1) and feed out HIP module (2) in direction of arrow.
Installation:
Make sure front guides (3) of HIP module (2) are correctly seated.
Fig. 131: Identifying Catches, HIP Module, Front Guides And Removal Direction
Disconnect plug connection (1) in direction of arrow and remove HIP module (2).
2007 BMW 335i
Fig. 132: Identifying Plug Connection, HIP Module And Removal Direction
After installation:
 Cars with out-of-date software status at time of repair:
After replacing the HIP module, program the Car Communication Computer. Then take the car for an
initialization drive.
 Cars with current software status at time of repair:
After replacing the HIP module, take the car for an initialization drive.
Initialization drive:
Drive for 15-20 minutes at 50 km/h and with good GPS reception until correct vehicle position is achieved in
the navigation display.
NOTE: During this time, the position pointer of the navigation system can be
motionless or move across country.
NAVIGATION SYSTEMS
65 90... NOTES ON HANDLING NAVIGATION COMPUTERS
All model series:
CAUTION: Risk of damage!
The navigation computer must not be disconnected from the power supply
while the LED on the computer remains lit (the LED goes out after approx.
1 minute).
2007 BMW 335i
NOTE: To ensure full operation of all the communications components, it is necessary

in new cars to insert a Road Map CD in the navigation computer.
This is absolutely essential as certain functions are disabled for distribution

channels.
These functions will only be available again after a Road Map CD has been
inserted. The mode preset at the factory is automatically reset when this CD is
inserted.
Software installation:
The navigation software must be loaded with terminal 15 activated and the navigation system ready for
operation.
Make sure there is a stable power supply. If necessary, connect a battery charger to the vehicle.
The charging operation must not be interrupted (terminal 15 remains activated).
When replacing navigation computer:
From E65/66:
 Carry out coding of navigation computer with aid of Diagnosis and Information System via "CIP".
To E65/66:
 Carry out coding of navigation computer with aid of Diagnosis and Information System in path "1
Recoding".
E46 (with radio navigation) only:
When replacing navigation computer:
 Connect Diagnosis and Information System to vehicle.

 Switch on ignition.
 Select Coding/Programming.
 Select path "3 Coding ZCS".
 Select vehicle.
 Select path "4 Retrofitting".
 Select menu item "3 Instrument cluster".
 Select menu item "2 Language".
 Select the desired languages following the user prompting.
 Start coding of the instrument cluster.
2007 BMW 335i
 After the prompt from the Diagnosis and Information System "Now follow the instructions on the on-
board monitor", insert the operating software CD.
 The following note appears from DIS CD 25 software (and higher):
"With radio navigation insert the operating software CD in the computer and wait until it is ejected. Then
follow the instructions on the display. This procedure takes several minutes".
NOTE: The ignition must not be turned off and then on again during this procedure.
The software is loaded when the operating software CD is ejected.
 Carry out coding of navigation computer with aid of Diagnosis and Information System in path "1
Recoding".
If the software is updated at a later stage, the last step is omitted if the navigation computer is already
configured for a navigation system (radio navigation or navigation system).
2007 BMW 335i
TRANSMISSION Automatic Transmission - Repair - N54
TRANSMISSION
Automatic Transmission - Repair - N54
AUTOMATIC TRANSMISSION
24 00 018 ADJUSTING SELECTOR LEVER (A5S 360R / 390R, A4S 200R, 6HP26Z/19Z)
NOTE: Check cable for ease of movement.

Move selector lever to "P" position.
Grip clamping sleeve (1).
Slacken nut (2).
Press selector lever (3) forwards into park position.
Press cable (4) in direction of arrow and release again.
Grip clamping sleeve (1).
Tighten down nut (2).
Tightening torque 25 16 2AZ .
Fig. 1: Pressing Selector Lever Forwards Into Park Position

Installation

2007 BMW 335i
Check whether parking gear is engaged by turning propeller shaft.
24 00 018 ADJUSTING SHIFT LEVER
NOTE: Check cable for ease of movement.

Press gear lever (1) forward into park position.
Clip shift cable head (2) onto ball head of gear lever.
Release bolt (3).
Press cable (4) in direction of arrow, then release again.
Tighten screw (3).
Fig. 2: Pressing Gear Lever Forward Into Park Position

Installation
Check whether parking gear is engaged by turning propeller shaft.
00 11 237 CHECKING/TOPPING UP FLUID LEVEL IN AUTOMATIC TRANSMISSION

(GA6HP19Z/6HP19Z AWD
IMPORTANT: Use only the approved transmission fluid . See AUTOMATIC TRANSMISSION -
2007 BMW 335i
OPERATING FLUIDS .
Failure to comply with this requirement will result in serious damage to the
automatic transmission!
Remove exhaust system bracket (1).
Fig. 3: Identifying Exhaust System Bracket

Installation:
Tighten down filler plug using
1. Hexagon wrench 8 A/F

2. torque wrench
3. Socket 8 A/F
Fig. 4: Locating Hexagon Wrench

2007 BMW 335i
Topping up transmission fluid after a repair
Stand vehicle on a level surface and secure against rolling off.
Undo filler plug (1).
Installation
Replace sealing ring.
Top up transmission fluid until it emerges from filling orifice.
Start engine.
Replenish transmission fluid until it emerges from filling orifice.
Fig. 5: Identifying Transmission Fluid Filler Plug

Screw in filler plug (1).
Tightening torque: 24 11 7AZ .
Press brake pedal to floor and shift through all gears several times at idle speed. Then shift to "P" position
(Park).
Then check fluid level.
Checking fluid level
 Connect BMW Diagnosis and Information System (DIS) or BMW MoDiC to vehicle.
2007 BMW 335i
 Call up Service functions (drive).

 Carry out fluid level check in accordance with instructions.
00 DANGER OF POISONING IF OIL IS INGESTED/ABSORBED THROUGH THE SKIN
Danger of poisoning!
Ingesting oil or absorbing through the skin may cause poisoning!
Possible symptoms are:
 Headaches
 Dizziness
 Stomach aches
 Vomiting
 Diarrhoea
 Cramps/fits
 Unconsciousness
Protective measures/rules of conduct
 Pour oil only into appropriately marked containers

 Do not pour oil into drinking vessels (drinks bottles, glasses, cups or mugs)
 Observe country-specific safety regulations
First aid measures
 Do not induce vomiting.
If the person affected is still conscious, he/she must rinse out their mouth with water, drink plenty of water and
consult a doctor immediately.
If the person affected is unconscious, do not administer anything by mouth, place the person in the recovery
position and seek immediate medical attention.
24 00 050 INSTALLING EXCHANGE TRANSMISSION (GA6HP19Z) ALL-WHEEL DRIVE

VEHICLE
Drain automatic transmission fluid at oil drain plug.
IMPORTANT: After completion of work, program transmission control unit.

2007 BMW 335i
Recycling
Catch and dispose of escaping transmission oil.
Observe country-specific waste disposal regulations
IMPORTANT:  Before installing exchange transmission, always flush transmission oil

cooler together with lines .
 After completion of repair work, check transmission oil level.
Exchange transmission is supplied filled with transmission oil.
Use only the approved transmission oil . See AUTOMATIC TRANSMISSION - OPERATING FLUIDS .
Failure to comply with this instruction will result in serious damage to the transmission.
 Remove automatic transmission (GA6HP19Z) N54/N55.

 Remove transfer box .
 Modify holder.
Convert transportation retainer (1).
Convert all cable clips.
Convert all seal plugs.
Convert protective cap on output shaft.
IMPORTANT: After removing transportation retainer, secure torque converter against

slipping out.
Transmission identification:
 refer to BMW Parts Department.

 On type plate
2007 BMW 335i
Fig. 6: Identifying Transmission

24 00 030 REMOVING AND INSTALLING AUTOMATIC TRANSMISSION (6HP19Z) N52/N53 4WD
 00 2 030
 00 9 010
 00 9 120
 00 9 130
 23 4 050
 24 1 110
 24 1 370
 24 2 390
IMPORTANT: After completion of repair work, check transmission oil level.

Use only the approved transmission oil . See AUTOMATIC TRANSMISSION -
OPERATING FLUIDS .
IMPORTANT: Aluminium-magnesium materials.

No steel screws/bolts may be used due to the threat of electrochemical
corrosion.
A magnesium crankcase requires aluminum screws/bolts exclusively.
Aluminum screws/bolts must be replaced each time they are released .
Aluminum screws/bolts are permitted with and without color coding (blue).
For reliable identification:

2007 BMW 335i
Aluminum screws/bolts are not magnetic .
Jointing torque and angle of rotation must be observed without fail (risk of damage) .
 Disconnect battery earth lead . See 6120900 DISCONNECTING AND CONNECTING BATTERY
NEGATIVE LEAD (E90) , 61 20 900 DISCONNECTING AND CONNECTING BATTERY
NEGATIVE LEAD (E90/E91) or 61 20 900 DISCONNECTING AND CONNECTING BATTERY
NEGATIVE LEAD (E92/E93) .
 Remove underbody protection with holder at front and rear.
 Remove center silencer (N53 only)
 Remove complete exhaust system
 Remove reinforcement plate . See 31 10 010 REMOVING AND INSTALLING/REPLACING
REINFORCEMENT PLATE (AWD) (E90) or 3110010 REMOVING AND
INSTALLING/REPLACING REINFORCEMENT PLATE (AWD) (E91/E92) .
 Remove FRONT PROPELLER SHAFT .
 Remove heat shields
 Support engine
Release screws.
Remove heat shield (1).
Fig. 7: Unscrewing Connector

Move selector lever to parking position "P".
Release screw (1).

2007 BMW 335i
Remove clamping bracket (2).
Release shift cable head (3) using a screwdriver from ball head of shift cable lever.
Installation note:
Adjust selector lever.
Fig. 8: Inserting Special Tool (24 2 390) In Sealing Sleeve

Disconnect connector (1).
Unfasten screws (2).
Remove retaining plate (3).

2007 BMW 335i
Fig. 9: Locating Heat Shield Screws

Release aluminum screw (1) on right next to cable retaining plate with special tool 00 9 010 .
Aluminum screws must be replaced.
Fig. 10: Identifying Selector Lever Components

Insert special tool 24 1 370 into recess of transmission housing and secure with screw (1).
NOTE: Note installation position.

Lug (2) must point in opposite direction to direction of travel!
2007 BMW 335i
Fig. 11: Identifying Connector, Screws And Retaining Plate

Supporting transmission
Support transmission with special tools 23 4 050 , 00 2 030 .
Secure transmission to mounting with tensioning strap (1).
Tasks are described in Gearbox holder .
After completion of work, check transmission fluid level.
Fig. 12: Identifying Aluminum Screw

 Remove transmission cross member . See 22 31 050 REPLACING CROSSMEMBER FOR

TRANSMISSION MOUNTING .
2007 BMW 335i
 Remove propeller shaft from transmission.

 Release center mount.
IMPORTANT:  Bending the propeller shaft by an excessive angle can cause premature
damage to the joint/propeller shaft!
 Tie up propeller shaft to underbody.
 Support engine with lifter when removing transmission.
 Unlock and disconnect connector (1) by turning.

 Do not touch pins.
 Release cable from brackets.
 Insert special tool 24 2 390 in sealing cup.
Repair work is described in Notes on mechatronics
IMPORTANT: Read and comply with important note.
Fig. 13: Identifying Screw And Lug

Release screw (1).
Disconnect hydraulic lines (2) to transmission oil cooler.
Installation note:
Replace sealing rings.

2007 BMW 335i
Fig. 14: Identifying Tensioning Strap And Transmission Supporting Special Tools
Release nut (1) and bracket from transmission oil lines on oil sump.

Crank engine at vibration damper in direction of rotation until screw (1) is visible in recess.
Release all bolts of torque converter with special tool 24 1 110 .
Crank engine further and release remaining 5 bolts.

2007 BMW 335i
Fig. 16: Identifying Transmission Oil Cooler Hydraulic Lines And Screw
Release screws.
Installation note:
Observe screw fastening sequence without fail.
Tightening torque, steel screws 24 00 1AZ .
Tightening torque and angle of rotation, aluminum screws/bolts 24 00 2AZ .
Fig. 17: Identifying Transmission Oil Lines Bracket Nut

Installation note:
2007 BMW 335i
Tighten down screws/bolts to specified torque.
Attach special tool 00 9 120 for angle of rotation with magnet 00 9 130
Secure to floor plate and screw down aluminum screws/bolts in accordance with angle of rotation.
Angle of rotation 24 00 2AZ .
Fig. 18: Identifying Vibration Damper Screw

Installation note:
Bore hole (1) of drive plate must be accessible from recess on engine oil sump. Check fitting sleeves (2...3) for
correct seating.
Replace damaged fitting sleeves.
Fig. 19: Identifying Automatic Transmission Screw Fastening Sequence

2007 BMW 335i
Installation note:
Rotate torque converter until bore hole in torque converter is flush with bore hole in driving plate.
Flange automatic transmission to engine.
24 00 030 REMOVING AND INSTALLING AUTOMATIC TRANSMISSION (6HP19Z) ALL-WHEEL

DRIVE VEHICLE
 00 2 030
 00 9 010
 00 9 120
 00 9 130
 23 4 050
 24 1 110
 24 1 370
 24 2 390

OPERATING FLUIDS .
IMPORTANT: Aluminum screws/bolts must be replaced each time they are released .
Jointing torque and angle of rotation must be observed without fail (risk of
damage) .
 Disconnect battery earth lead . See 6120900 DISCONNECTING AND CONNECTING BATTERY
 Remove complete exhaust system . See EXHAUST SYSTEM, COMPLETE .
2007 BMW 335i

 Remove fan cowl . See 17 11 035 REMOVE AND INSTALL OR REPLACE THE FAN COWL
WITH ELECTRIC FAN(N53, N54, N54T, N55) .
 Remove propeller shaft from transmission.
 Release center mount.
IMPORTANT:  Bending the propeller shaft by an excessive angle can cause premature
 Tie up propeller shaft to underbody.
 Support engine with lifter when removing transmission.
Release screws (1).
Fig. 20: Connecting Special Tool For Angle Of Rotation With Magnet (00 9 130)
Release screws.

2007 BMW 335i
Fig. 21: Identifying Bore Hole And Fitting Sleeves

Remove cables (1) from holder (3).
Release screw (2) and remove holder (3).
Fig. 22: Identifying Transmission Bracket Bolts

Release screw (1).
2007 BMW 335i
Installation note:
Adjust gearshift lever.
Fig. 23: Locating Heat Shield Bolts

Fig. 24: Identifying Cables, Screw And Holder

Release aluminum screw (1) on right next to cable retaining plate with special tool 00 9 010 .
2007 BMW 335i

Insert special tool 24 1 370 into recess of transmission housing and secure with screw (1).
NOTE: Check installation position.
Lug (2) must point in opposite direction to direction of travel!
Fig. 26: Identifying Connector, Screws And Retaining Plate

2007 BMW 335i
Repair work is described in Gearbox holder .
Fig. 27: Identifying Retaining Plate Aluminum Screw

Release screws.
Remove transmission cross member. See 22 31 050 REPLACING CROSSMEMBER FOR

Fig. 28: Identifying Screw And Lug

2007 BMW 335i
Disconnect plugs (1) and (2) from servomotor.
Fig. 29: Identifying Tensioning Strap And Transmission Supporting Tools


Fig. 30: Locating Transmission Cross Member Bolts

2007 BMW 335i
Release screw (1).
Installation note:
Fig. 31: Identifying Servomotor Plugs



2007 BMW 335i
Graphic similar.
Lower transmission and lock with a suitable block (1) between front axle support and oil sump.

Release screws.
Installation note:

2007 BMW 335i
Tightening torque and angle of rotation, aluminum screws/bolts (7, 8, 9, 10, 11) 24 00 2AZ .

Installation note:
Secure to vehicle underbody and screw down aluminum screws/bolts in accordance with angle of rotation.
Fig. 36: Identifying Block Between Front Axle Support And Oil Sump
2007 BMW 335i
Installation note:
Bore hole (1) of drive plate must be accessible from recess on engine oil sump. Check fitting sleeves (2...3) for
correct seating.
Fig. 37: Identifying Aluminum Screws/Bolts Tightening Sequence

Installation note:
Rotate torque converter until bore hole in torque converter is flush with bore hole in driving plate.
24 00 030 REMOVING AND INSTALLING AUTOMATIC TRANSMISSION (GA6HP19Z) N54/N55
 00 2 030
 00 9 120
 00 9 130
 23 4 050
 24 1 110
 24 2 390
 24 4 160
 24 4 161
 24 4 165
IMPORTANT: After completion of work, check transmission oil level.

2007 BMW 335i

OPERATING FLUIDS .
damage) .

 Remove fan cowl with fan. See 17 11 035 REMOVE AND INSTALL OR REPLACE THE FAN
COWL WITH ELECTRIC FAN(N53, N54, N54T, N55) .
 Release the hose connector from the charge air cooler on the left and right.
 Support engine with jack when removing transmission
Release screws (1).
Bracket remove.
2007 BMW 335i
Fig. 39: Identifying Bore Hole And Fitting Sleeves

Release and disconnect plug connectors (1) from brackets.
Remove cover plate (3).
NOTE: Graphic similar

2007 BMW 335i
Fig. 40: Identifying Screws, Heat Shield And Connector

Release aluminum bolt (1) on right next to cable retaining plate.

Grip clamping bush (1).
Slacken nut (2).
Detach clamp (3) downwards using a screwdriver.
Pull cable (4) out of holder.
Installation note:

2007 BMW 335i
Fig. 42: Identifying Plug Connectors, Screws And Cover Plate

Tasks are described in Gearbox holder .
Fig. 43: Identifying Retaining Plate Aluminum Bolt

Unfasten screws (1) and nuts (2).
Remove transmission cross-member.

2007 BMW 335i
Tightening torque 24 71 1AZ/2AZ .
Fig. 44: Identifying Grip Clamping Bush, Slacken Nut, Clamp And Cable
 Remove propeller shaft from transmission. See 26 11 000 REMOVING AND INSTALLING
COMPLETE PROPELLER SHAFT (FLEXIBLE DISC AT REAR) (AWD) , 2611000
REMOVING AND INSTALLING PROPELLER SHAFT (CARDAN UNIVERSAL JOINT)
COMPLETELY (E90) or 26 11 000 REMOVING AND INSTALLING PROPELLER SHAFT
(CARDAN UNIVERSAL JOINT) COMPLETELY (E90/E91) or 26 20 000 REMOVING AND
INSTALLING FRONT PROPELLER SHAFT (E92/E93) .
 Release center mount.
IMPORTANT:  Bending the propeller shaft by an excessive angle can cause premature
 Tie up propeller shaft to underbody.
 Support engine with lifter when removing transmission.
Release screw (1).
Installation note:

2007 BMW 335i
Fig. 46: Identifying Transmission Cross-Member Screws And Nuts


2007 BMW 335i
Prepare special tool (1) 24 4 161 (A) with shaped element (2) 24 4 165 , side (B) to (A).

Insert special tool 24 4 160 into recess of transmission housing and clamp gently with screw (1).
Raise by turning screw (2) and clamp down.
Then tighten down screw (1).

2007 BMW 335i


Fig. 50: Identifying Special Tool And Shaped Element

Release screws.
Installation note:
2007 BMW 335i
Observe screw fastening sequence without fail.
Tightening torque and angle of rotation, aluminum screws/bolts 24 00 2AZ (7, 8, 9, 10, 11).
Fig. 51: Inserting Special Tool (24 4 160) Into Recess Of Transmission Housing
Installation note:
Secure to vehicle underbody and screw down aluminum screws/bolts in accordance with angle of rotation.

2007 BMW 335i

Installation note:
Bore hole (1) of driving plate must be accessible from recess on engine oil sump.
Fig. 53: Identifying Aluminum Screws/Bolts Tightening Sequence

Check that fitting sleeves are correctly fitted.

2007 BMW 335i
Installation note:
Rotate torque converter until bore hole in torque converter is flush with bore hole in drive plate.
00 RISK OF INJURY IF OIL COMES INTO CONTACT WITH EYES AND SKIN
Danger of injury!
Contact with eyes or skin may result in injury!
 Impaired sight
 Irritation of the eyes
 Reddening of the skin
 Rough and cracked skin
 Wear protective goggles

 Wear oil-resistant protective gloves
First aid measures
 Eye contact: Rinse eyes immediately with plenty of water for at least 15 minutes; if available, use an eye-
rinsing bottle. If irritation of the eyes persists, consult a doctor.
2007 BMW 335i
 Skin contact: Wash off with soap and water immediately. If irritation persists, consult a doctor.
NOTE: Do not use solvents/thinners.
00 SAFETY INSTRUCTIONS FOR HANDLING OIL
WARNING: Danger of poisoning if oil is ingested/absorbed through the skin!

Risk of injury if oil comes into contact with eyes and skin!
Recycling
Observe country-specific waste-disposal regulations.
Measures if oil is unintentionally released
 Personal precautionary measures: Danger of slipping! Keep non-involved persons away from the work
area. Wear personal protective clothing/equipment.
 Environmental protection measures: Prevent oil from draining into drain channels, sewerage systems,
pits, cellars, water and the ground.
 Limiting spread: Use oil blocks to prevent the surface spread of oil.
 Cleaning procedure: Bind and dispose of escaped oil with nonflammable absorbents.
NOTE: Do not flush oil away with water or aqueous cleaning agents.
23 TRANSMISSION DESIGNATIONS
Breakdown of BMW designation
A5S 300J (former designation)

 S = Manual gearbox
A Transmission type
 A = Automatic transmission
5 Number of forward gears
 D = Direct gear
S Type of top gear
 S = Overdrive gear
300 Max. input torque (Nm)
G = Getrag

 J = Jatco
J Code letter of transmission manufacturer
 R = GMPT (General Motors Powertrain)
 Z = ZF (Zahnradfabrik Friedrichshafen)
SMG Notes SMG = Sequential M gearbox/transmission

2007 BMW 335i
GS6-37BZ (new designation according to BMW Group Standard GS 90007)

G Transmission
S Transmission type
 - = Standard with manual gearshift
-  HP = Hydraulic planetary gear
 DKG= twin-clutch gearbox
 26 = D-transmission
 31 = C-transmission
 39 = F-transmission
 37 = H-transmission
37 Transmission type  53 = G-transmission
 17 = I-transmission
 47= J transmission SMG -7-speed
 45 = K transmission
 36= Transmission DKG
 B = Petrol gear ratio
B Gear set  D = Diesel gear ratio
 S= Sport gear ratio
 G = Getrag
Z Code letter of transmission manufacturer
Manual gearbox
BMW designation Manufacturer Manufacturer designation Remarks

S5D 200G Getrag B transmission (220/5)
S5D 200G Getrag B transmission (221/5) for M41 engine only
S5D 250G Getrag B transmission (220/5) Reinforced version
S5D 260Z ZF C-transmission (S5-31 D) for M51 engine only
S5D 280Z ZF C-transmission (S5-31)
S5D 310Z ZF C-transmission (S5-31) up to 9.95
S5D 320Z ZF C-transmission (S5-31) from 9.95 (reinforced version)
GS5S31BZ (SMG) ZF C transmission SMG
GS5-39DZ ZF F transmission
S6S 420G Getrag D-transmission (226/6)
S6S 420G (SMG) Getrag D transmission SMG
S6S 560G Getrag E-transmission (286/6)
GS6-37BZ ZF H-transmission
2007 BMW 335i
GS6S37BZ (SMG) ZF H-transmission

GS6-37DZ ZF H-transmission
GS6-37BG Getrag H-transmission
GS6-53BZ ZF G-transmission
GS6-53DZ ZF G-transmission
GS6-17BG Getrag I-transmission
GS6-17DG Getrag I-transmission
GS7S47BG (SMG) Getrag J-transmission (247) SMG -7-gear
GS7D36SG Getrag DKG (436) DKG -7-gear
GS6-45BZ ZF K transmission
GS6-45DZ ZF K transmission
Automatic transmission

A4S 200R General Motors Powertrain GM4
A4S 270R General Motors Powertrain THM-R1w Transmission wide-stepped
A4S 310R General Motors Powertrain THM-R1
A5S 300J Jatco Jatco
A5S 310Z ZF 5HP-18
A5S 325Z ZF 5HP-19
A5S 440Z ZF 5HP-24
A5S 560Z ZF 5HP-30
A5S 360R / 390R GM GM5
GA6HP19Z ZF 6HP19
GA6HP26Z ZF 6HP26
GA6HP32Z ZF 6HP32
GA6L45R GM GM6
GA8HP45Z ZF 8HP45
GA8HP70Z ZF 8HP70
GA8P70H ZF 8P70 Hybrid
GA8HP90Z ZF 8HP90
GA7AHSCD Daimler AHS-C Hybrid
23... UNIVERSAL BMW TRANSMISSION TAKE-UP
 00 2 030
 23 4 050
NOTE:  The universal transmission bracket is introduced for the E60 AWD.
2007 BMW 335i
 Suitable for manual and automatic transmissions.
IMPORTANT: Front and rear supports (1) can be laterally adjusted by means of screws (2).
Carrier (3) of rear supports (1) can be longitudinally adjusted by means of
screw.
Supports must be adapted in length and width to the transmission.
Fig. 55: Identifying Bore Hole Of Driving Plate

IMPORTANT: Transmission must be secured with tensioning strap (1).
Fig. 56: Identifying Fitting Sleeves

2007 BMW 335i
23..... UNIVERSAL TRANSMISSION RETAINING BRIDGE
 00 1 450
 24 0 200
NOTE:  The transmission retaining bridge 24 0 200 is suitable for both manual and
automatic transmissions.
IMPORTANT: Adapters and spindles must be adapted for positive locking to the
transmission.
(Risk of injury)
Adapt adapters (1) and spindle with thrust piece (3) to transmission.
Adapt length with slide (2).
Screw in spindle (4).
IMPORTANT: Before mounting on assembly stand 00 1 450 , check retaining bridge for
secure seating.
Fig. 57: Removing Torque Converter Using Special Tool (24 4 000)
TRANSMISSION CASE, OIL SUMP

2007 BMW 335i
24 11 011 REMOVING AND INSTALLING/SEALING OR REPLACING TRANSMISSION OIL SUMP

(GA6HP19Z)
IMPORTANT:  Do not let skin come in contact with transmission oil and do not inhale
fuel vapors.
 Wear protective gloves.
 Ensure adequate ventilation.
IMPORTANT: Remove transmission oil sump only after it has cooled down.
After completion of repair work, check transmission oil level.
Use only the approved gearbox oil . See AUTOMATIC TRANSMISSION -
OPERATING FLUIDS .
Recycling
Catch and dispose of escaping automatic transmission fluid.
Observe country-specific waste disposal regulations.
Remove rear underbody protection. See 5147491 REMOVING AND INSTALLING/REPLACING REAR
UNDERBODY PROTECTION (E90) , 51 47 491 REMOVING AND INSTALLING/REPLACING
REAR UNDERBODY PROTECTION (E90/E91) or 51 47 491 REMOVING AND
INSTALLING/REPLACING REAR UNDERBODY PROTECTION (E92/E93) .
Remove exhaust bracket from transmission.
Remove oil drain plug (1).
Drain automatic transmission oil.
Installation note:
Replace oil drain plug.

2007 BMW 335i
Fig. 58: Removing Torque Converter

Unscrew all bolts.
Remove transmission oil sump (1).
IMPORTANT: Transmission with plastic oil sump

From 11/04, new M6x28.5 T40 Torx screw can be retrospectively replaced.
Installation note:
Insert screws (2) until screw heads make contact.
Insert all further screws in diagonal sequence from inside to outside until screw heads make contact.

2007 BMW 335i
Fig. 59: Identifying Automatic Transmission Oil Drain Plug

Remove gasket (1) from transmission sump.
Clean sealing faces and groove with a cloth.
Insert new gasket in transmission oil sump groove.
IMPORTANT: Do not degrease transmission oil sump with cleaning agent.
Fig. 60: Locating Transmission Oil Sump Screws

Replace sealing ring (1) on oil filter tube.
Fig. 61: Identifying Transmission Sump Gasket

2007 BMW 335i
Installation note:
The gasket is correctly installed when it is engaged in the locating opening of the transmission oil sump.
Fig. 62: Identifying Sealing Ring On Oil Filter Tube

EXTENSION HOUSING, BEARINGS, SEAL

24 13 013 REPLACING OUTPUT FLANGE SHAFT SEAL (GA6HP19Z) AWD
 23 0 490
 24 4 310

OPERATING FLUIDS .
 Remove transfer box .
Drive a hole into radial shaft seal (1) using a center punch.
IMPORTANT: Do not use a drill as drillings may result in transmission malfunction.
Thread special tool 23 0 490 into radial shaft seal (1).

2007 BMW 335i
Drive out radial shaft seal (1) with impact weight (2).
Fig. 63: Locating Transmission Oil Sump Mounting Screw

Installation note:
Coat sealing lips of new radial shaft seal with clean transmission oil.
Drive shaft seal firmly home with special tool 24 4 310 .
MECHANICAL ATTACHMENTS
24 14 005 REPLACING SEALING CAP FOR SELECTOR SHAFT (GA6L45R), FOUR-WHEEL
DRIVE
2007 BMW 335i
 23 0 490

Use only the approved automatic transmission oil in this automatic
transmission. See AUTOMATIC TRANSMISSION - OPERATING FLUIDS .
Failure to comply with this requirement will result in serious damage to the automatic transmission!
 Remove rear underbody protection . See 5147491 REMOVING AND INSTALLING/REPLACING

REAR UNDERBODY PROTECTION (E90) , 51 47 491 REMOVING AND
INSTALLING/REPLACING REAR UNDERBODY PROTECTION (E90/E91) or 51 47 491
REMOVING AND INSTALLING/REPLACING REAR UNDERBODY PROTECTION
(E92/E93) .
 Remove front propeller shaft at transfer box and tie to one side.
 Tasks are described in removing FRONT PROPELLER SHAFT .
Screw special tool 23 0 490 into sealing cap.
Drive out sealing cap using impact weight (1).
IMPORTANT: Clean bore hole using a clean cloth and ensure that there is no more oil
sticking to it.

Place new sealing cap (1) on drift (3).

2007 BMW 335i
IMPORTANT: Sealing cap (1) must be inserted into transmission housing with sealing lip (2).
NOTE: Drift (3) for driving in sealing cap is contained in repair kit.
Fig. 66: Identifying Cable And Holder

Drive in new sealing cap (1) to the stop with drift (2).
Fig. 67: Identifying Shift Cable Head, Clamp And Cable

24 14 002 REPLACING SELECTOR SHAFT SEAL (GA6HP19)
 24 5 361
 24 5 362
2007 BMW 335i
 24 5 364
 24 5 366

Use only the approved transmission fluid . See AUTOMATIC TRANSMISSION -
OPERATING FLUIDS .
 Remove heat shields
NOTE: Version 1:
Grip clamping sleeve (1) and slacken nut (2).
Detach retainer (3) downwards using a screwdriver.
Installation:
Fig. 68: Securing Lever Using Cable Strap Or Wire

NOTE: Version 2:
Release shift cable head (1) from ball head.

2007 BMW 335i
Installation:
Adjust selector lever.

Slacken nut (1).
Take off holder (2).
Fig. 70: Identifying Bracket Screws

Screw in special tool 24 5 361 until it is firmly connected with radial shaft seal hat.
2007 BMW 335i

Screw special tool 24 5 362 onto special tool 24 5 361 and tighten down.
This pulls the shaft seal out of the transmission housing.
Fig. 72: Inserting Special Tool (24 2 390) In Sealing Sleeve

Oil sealing lip on shaft seal (1).
Screw in radial shaft seal (1) with special tools 24 5 366 and 24 5 364 as far as it will go.
2007 BMW 335i
Fig. 73: Removing Transmission Oil Sump

OIL PUMP
24 31 575 REPLACING OIL PUMP O-RINGS (GA6HP26/19Z)
 24 1 180
 24 1 184

Use only approved transmission oil. See AUTOMATIC TRANSMISSION -
OPERATING FLUIDS . See 24 00 030 REMOVING AND INSTALLING
AUTOMATIC TRANSMISSION (6HP19Z) N52/N53 4WD or 24 00 030 REMOVING
AND INSTALLING AUTOMATIC TRANSMISSION (GA6HP19Z) N54/N55 or 24 00
030 REMOVING AND INSTALLING AUTOMATIC TRANSMISSION (6HP19Z)
N52/N53 4WD.
Failure to comply with this instruction will result in serious damage to the
transmission.
 Remove automatic transmission .

 Secure transmission with transmission holding bridge on assembly stand.
 Remove torque converter.
 Remove mechatronics .
Remove adapter (1).

2007 BMW 335i
Installation note:
Note installation position.
Fig. 74: Pulling Out Sealing Cup

Release screws.
Fig. 75: Identifying Mechatronics Screws

Slide special tool 24 1 184 completely into puller 24 1 180 .

2007 BMW 335i

Attach special tool 24 1 180 and secure with screw (1).
Insert screw (2) and release oil supply unit from transmission housing.
Fig. 77: Identifying Mechatronics Solenoid Valve

Release screws.

2007 BMW 335i
Fig. 78: Identifying Mechatronics Protective Bar

Detach cover (1) from pump housing (2).
Replace O-rings (3 + 4).
Installation note:
Pay attention to installation position of gears during disassembly.
Fig. 79: Identifying Automatic Transmission Gaskets

24 31 011 REPLACING TORQUE CONVERTER SHAFT SEAL (GA6HP19Z)
 00 1 450
2007 BMW 335i
 24 0 200
 24 2 351
 24 2 352
 24 2 353
 24 2 400
 Remove AUTOMATIC TRANSMISSION.

Use only approved transmission oil . See AUTOMATIC TRANSMISSION -
OPERATING FLUIDS .
transmission.
Secure transmission with special tool 24 0 200 on assembly stand 00 1 450 .
Remove torque converter.
NOTE: Read and comply with installation note on transmission retaining bridge .

Attach special tool 24 2 353 to input shaft (1).

2007 BMW 335i
Fig. 81: Identifying Mechatronics Screws Tightening Sequence

Screw in special tool 24 2 351 until it is firmly connected with radial shaft seal.
Screw in special tool 24 2 352 to remove radial shaft seal.
Fig. 82: Identifying Mechatronics Screws Tightening Sequence

Oil sealing lip on shaft seal.
Drive in radial shaft seal (1) with special tool 24 2 400 as far as it will go.
2007 BMW 335i
Fig. 83: Identifying Transmission Adapter

SHIFT VALVES, PARKING LOCK

24 34... NOTES ON MECHATRONICS (GA6HP26Z/GA6HP32Z/GA6HP19Z
 24 2 390
IMPORTANT: After completing repair work:
 Load specific data status with DIS

 Check transmission oil level.

OPERATING FLUIDS .
IMPORTANT: Read and comply with notes on protection against electrostatic discharge (ESD
protection) . See 6135... NOTES ON ESD PROTECTION (ELECTRO STATIC
DISCHARGE) (E90) , 61 35... NOTES ON ESD PROTECTION (ELECTRO STATIC
DISCHARGE) (E90/E91 or 61 35... NOTES ON ESD PROTECTION (ELECTRO
STATIC DISCHARGE) (E92/E93) .
Unscrew connector (1) and disconnect.

2007 BMW 335i
Fig. 84: Locating Transmission Screws

Insert special tool 24 2 390 in sealing sleeve (1).
Fig. 85: Sliding Special Tool (24 1 184) Completely Into Puller
24 34 562 REPLACING MECHATRONICS (GA6HP19Z)
 24 2 390
NOTE: After completing work:
 Load specific data status with the BMW diagnosis system.

2007 BMW 335i

Use only approved gearbox oil . See AUTOMATIC TRANSMISSION -
OPERATING FLUIDS .
protection) . See 6135... NOTES ON ESD PROTECTION (ELECTRO STATIC
DISCHARGE) (E90) , 61 35... NOTES ON ESD PROTECTION (ELECTRO STATIC
DISCHARGE) (E90/E91 or 61 35... NOTES ON ESD PROTECTION (ELECTRO
STATIC DISCHARGE) (E92/E93) .
 Remove heat shields.

 Support the automatic transmission with hydraulic lifting equipment.
 Remove transmission cross-member . See 22 31 050 REPLACING CROSSMEMBER FOR
Version 1:
Grip clamping bush (1) and slacken nut (2).
Installation note:
Fig. 86: Releasing Oil Supply Unit From Transmission Housing Using Tool
2007 BMW 335i
Version 2:
Release screw (1).
Installation note:
Fig. 87: Locating Transmission Cover Screws

Version 3:
Unfasten nut.
Remove cable (1).
Installation note:
Adjusting cable:
 Release nut
 Adjust cable by means of holder (2) until spacing A = 1 mm is obtained
 Tighten down nut
2007 BMW 335i
Fig. 88: Identifying Cover, Pump Housing And O-Rings

Version 4:
Move selector lever to "Parking".
Release shift cable head (1) using a screwdriver from ball head of gearshift lever.
Slide cable (3) towards rear and disengaged in downward direction.
Installation note:
Adjusting gearshift lever
Fig. 89: Driving Out Radial Shaft Seal Using Impact Weight
2007 BMW 335i
Secure lever (1) with a cable strap (2) or wire in vertical position.
NOTE: E65 only.
Fig. 90: Driving Shaft Seal Using Special Tool (24 4 310)
only M57T2
Release screws (1).
Fig. 91: Driving Out Sealing Cap Using Impact Weight

only M57T2
Release screws (1).

2007 BMW 335i
Bracket remove.
Fig. 92: Identifying Sealing Cap, Sealing Lip And Drift

IMPORTANT: Mechatronics can be destroyed by static discharges. Therefore the contacts

inside the connector must not be touched. Insert special tool immediately after
operation.
Unscrew connector (1) and disconnect.
Fig. 93: Driving Sealing Cap Using Drift

Insert special tool 24 2 390 in sealing cup (1).

2007 BMW 335i
Remove transmission oil sump.
Unlock sealing sleeve with slide (1).
Fig. 95: Identifying Shift Cable Components

Note position of sealing cup.
Pull out sealing cup (1).
Installation note:
Screw in sealing sleeve partially (lug in upper area).
Turn until lug engages in groove of transmission. Slide in sealing cup.

2007 BMW 335i
Lug on sealing sleeve must not be damaged!
Fig. 96: Identifying Shift Cable Nut And Holder

NOTE: GA6HP19Z
Release all screws (1 and 2).
 1 = M6 x 58 mm
 2 = M6 x 20 mm
Remove mechatronics.
Fig. 97: Identifying Special Tool (24 5 361)

NOTE: GA6HP19Z TU
2007 BMW 335i
Release all screws (1 and 2).
 1 = M6 x 59 mm
 2 = M6 x 20 mm
Remove mechatronics.
Fig. 98: Screwing Special Tool (24 5 362) Onto Special Tool (24 5 361)
IMPORTANT: Only installed in E65!

Mechatronics without protective bar for solenoid valve must not be reused
after removal.
Fig. 99: Screwing Radial Shaft Seal Using Special Tools (24 5 366) And (24 5 364)
IMPORTANT: Only installed in E65!

2007 BMW 335i
Fit/reuse only mechatronics with protective bar (1) for solenoid valve.
Fig. 100: Securing Transmission Using Special Tool (24 0 200)

Installation note:
Check gaskets (1 and 2) for damage, replace gaskets if necessary.
Coat new gaskets with automatic transmission fluid and install.
Fig. 101: Connecting Special Tool To Input Shaft

Installation note:
Insert screws (3) alternately until contact is made with each screw head.
2007 BMW 335i
Insert all further screws contact is made with each screw head.
Fig. 102: Removing Radial Shaft Seal Using Tools

NOTE: GA6HP19Z
IMPORTANT: Tighten down screws in order 1...10.

Fig. 103: Driving Radial Shaft Seal Using Special Tool (24 2 400)
NOTE: GA6HP19Z TU
2007 BMW 335i
IMPORTANT: Tighten down screws in order 1...13.

Fig. 104: Identifying Manual And Automatic Transmissions Front And Rear Supports, Carrier And
Screws
TORQUE CONVERTER
24 40 011 REMOVING AND INSTALLING/REPLACING TORQUE CONVERTER (GA6HP19Z)
 24 4 000

OPERATING FLUIDS .
transmission.
 Remove automatic transmission . See 24 00 030 REMOVING AND INSTALLING AUTOMATIC

TRANSMISSION (6HP19Z) N52/N53 4WD or 24 00 030 REMOVING AND INSTALLING
AUTOMATIC TRANSMISSION (6HP19Z) N52/N53 4WD.
Screw special tool 24 4 000 into torque converter.

2007 BMW 335i
Remove torque converter.
NOTE: When torque converter is removed, transmission oil flows out.
Fig. 105: Identifying Tensioning Strap And Transmission Supporting Tools

Installation note:
When installing, do not damage radial shaft seal and bearing.
If the torque converter is not correctly installed, the driver of the pump impeller may be damaged when the
transmission is flanged to the engine.
Remove torque converter and set down vertically.
Fig. 106: Identifying Assembly Stand (00 1 450) Components

2007 BMW 335i
Installation note:
Push torque converter through radial shaft seal onto transmission shaft to the limit position.
Press torque converter by hand into converter housing and turn in the process. Converter hub recess must snap
into place in driver of pump impeller. Torque converter must be felt to slip inwards.
2007 BMW 335i
2007-08 ENGINE Engine - Repair - 335i, 335xi
2007-08 ENGINE
Engine - Repair - 335i, 335xi
00 ENGINE GENERAL
 Headaches
 Dizziness
 Stomach aches
 Vomiting
 Diarrhoea
 Cramps/fits
 Unconsciousness
Protective measures/rules of conduct:

First aid measures:
If the person affected is still conscious, he/she must rinse out their mouth with water, drink plenty of
water and consult a doctor immediately.
If the person affected is unconscious, do not administer anything by mouth, place the person in the
recovery position and seek immediate medical attention.
Danger of injury!

2007 BMW 335i
 Impaired sight

First aid measures:
WARNING: Danger of poisoning if oil is ingested/absorbed through the skin! (See 00

DANGER OF POISONING IF OIL IS INGESTED/ABSORBED THROUGH THE
SKIN)
Risk of injury if oil comes into contact with eyes and skin! (See 00 RISK
OF INJURY IF OIL COMES INTO CONTACT WITH EYES AND SKIN)
Recycling:
Measures if oil is unintentionally released:
11 00 REMOVING AND INSTALLING/REPLACING ACOUSTIC COVER (N54)

2007 BMW 335i
 Remove microfilter housing (See 64 31 092 REMOVING AND INSTALLING/REPLACING

MICROFILTER HOUSING (LOWER SECTION) and/or 64 31 092 REMOVING AND
INSTALLING/REPLACING MICROFILTER HOUSING (LOWER SECTION) )
 E60/E61 only: Remove tension strut
Release screws.
Tightening torque, see 11 12 7AZ in ENGINE -- TORQUE SPECIFICATIONS -- TWIN TURBO .
Lift off acoustic cover (1)
NOTE: For purposes of improved clarity, illustration and descriptions shows wiring
harness and tension strut removed.
Fig. 1: Lifting Off Acoustic Cover

11 00 050 REMOVING AND INSTALLING ENGINE (N54)
 11 0 000
 11 5 281
 11 5 282
 11 7 310
 11 8 680
The end faces of aluminum screws/bolts are painted blue for the purposes of
reliable identification.
2007 BMW 335i
damage) .
 Disconnect negative battery lead.

 Lift engine hood into assembly position. (See 51 00 ... SERVICE POSITION OF ENGINE
HOOD/BONNET and/or 51 00 ... SERVICE POSITION OF ENGINE HOOD/BONNET )
 Drain engine oil.
 Remove air cleaner housing. (See 13 71 000 REMOVING AND INSTALLING/REPLACING
INTAKE FILTER HOUSING (N54) )
 Remove fan cowl with electric fan.
 Remove radiator.
 Detach all coolant hoses from engine.
 Remove left and right fresh air duct. (See 51 71 371 REMOVING AND INSTALLING/REPLACING
TENSION STRUT ON LEFT OR RIGHT SPRING STRUT DOME and/or 51 71 371 REMOVING
AND INSTALLING/REPLACING TENSION STRUT ON LEFT OR RIGHT SPRING STRUT
DOME )
 Remove intake air manifold. (See 11 61 050 REMOVING AND INSTALLING INTAKE AIR
MANIFOLD (N54))
 Detach vacuum line from brake booster.
 Unfasten ignition wiring harness and lay to one side. (See 12 51 100 REPLACING WIRING
HARNESS SECTION FOR IGNITION COIL (N54) )
 Unfasten engine wiring harness and lay to one side. (See 12 51 100 REPLACING WIRING HARNESS
SECTION FOR IGNITION COIL (N54) )
 Remove exhaust system.
 Remove transmission.
Support engine with special tool 11 7 310 on steering gear. (See 11 7 310 SPACER )
2007 BMW 335i

Evacuate A/C system.
Release screws (1) for A/C lines.
Disconnect plug connection (2) on A/C compressor.
Do not remove A/C compressor.
Fig. 3: Identifying Plug Connection On A/C Compressor & Screw

Release bolts (1 and 2) from power steering pump bracket.
Set power steering pump down on front axle carrier.
NOTE: Do not disconnect hydraulic lines.
If Dynamic Drive optional extra is fitted, release bracket.

2007 BMW 335i
Fig. 4: Identifying Bolts From Power Steering Pump Bracket

Disconnect fuel lines (1 and 2).
Seal off fuel line (1) with special tool 11 5 281.
Seal off fuel line (2) with special tool 11 5 282.
Fig. 5: Identifying Special Tool (13 5 281) & (13 5 282)

Secure special tool 11 8 680 to lifting eye on transmission side. (See 11 8 680 ADAPTER )
Press locking pin (1) in direction of arrow until locking balls (2) are loose.
Secure special tool 11 8 680 to lifting eye, release locking pin (1). (See 11 8 680 ADAPTER )
Installation:
Special tool 11 8 680 is correctly installed when locking balls (2) are arrested. (See 11 8 680 ADAPTER )
Special tool 11 8 680 is firmly secured to lifting eye. (See 11 8 680 ADAPTER )
2007 BMW 335i
Fig. 6: Identifying Locking Pin & Locking Balls

Suspend special tool 11 0 000 from special tool 11 8 680 in eye (1). (See 11 8 680 ADAPTER )

Screw in towing hook (1).
Suspend special tool 11 0 000 from engine crane.
Suspend special tool 11 0 000 from the designated mounting eyelets (2) only.
Unscrew left and right engine mounts.
Lift engine out with crane.

2007 BMW 335i

Installation:
Secure special tool 11 7 310 to steering gear. (See 11 7 310 SPACER )

Assemble engine.
Check function of DME.
11 00 670 SECURING ENGINE IN INSTALLATION POSITION (N54)
 00 0 200
 00 0 202
 00 0 204
2007 BMW 335i
 00 0 208
 11 0 020
 64 1 020
WARNING: Danger of injury!
Observe following instructions relating to special tool:
1. Prior to each use, check the special tools for defects, modifications and operational reliability.
2. Damaged/modified special tools must not be used!
3. No changes or modifications may be made to the special tools!
4. Keep special tools dry, clean and free of grease.
 Secure engine bonnet/hood in service position (See 51 00 ... SERVICE POSITION OF ENGINE
HOOD/BONNET and/or 51 00 ... SERVICE POSITION OF ENGINE HOOD/BONNET )
 Remove cowl panel cover (See 51 13 116 REMOVING AND INSTALLING COWL PANEL
COVER )
 Remove acoustic cover (See 51 13 116 REMOVING AND INSTALLING COWL PANEL COVER )
Only on E92, E93:
Unclip two cover caps (1) on left and right of side panel screw connection with special tool 64 1 020. (See 64 1
020 RELEASE HOOK )
Installation:
Replace damaged cover caps.

2007 BMW 335i
Assemble cross member 00 0 200 with special tools 00 0 202, 00 0 204, 00 0 208.

NOTE: Use towing hook (72 15 8 108 670).
Fig. 12: Identifying Special Tool (75 15 8 108 670)

IMPORTANT: Avoid a change of engine position in the transverse or longitudinal direction.
Always make sure there is sufficient clearance between the engine (or its
attachment parts) and the body.
With the aid of an assistant and the supports (2), place cross member 00 0 200
on the screw connections of the side panels.
2007 BMW 335i
Screw in towing hook (1) and tighten down to approx. 30 Nm.
Secure special tool 11 0 020 to spindle 00 0 202.
Fit suitable chains to special tool 11 0 020 and attach to towing hook (1) or engine lifting eye.
Fig. 13: Identifying Special Tool (00 0 202), (00 0 200) & (11 0 020)
Tighten down all adjusting screws and nuts on cross member 00 0 200.

Unscrew nuts (1).
Raise engine approx. 10 mm with cross member.
Installation:
2007 BMW 335i
Replace self-locking nuts.
Tightening torque, see 22 11 2AZ in 22 11 ENGINE SUSPENSION
Fig. 15: Identifying Self-Locking Nuts

ENGINE IDENTIFICATION
Drive in engine numbers at marked surface with impact tool.
M47/M47TU/M47T2
Fig. 16: Locating Engine Identification - (M47/M47TU/M47T2)

M57/M57TU/M57T2
2007 BMW 335i
Fig. 17: Locating Engine Identification - (M57/M57TU/M57T2)

M67/M67TU
Fig. 18: Locating Engine Identification - (M67/M67TU)

N47
2007 BMW 335i
Fig. 19: Locating Engine Identification - (N47)

M52/M52TU
Fig. 20: Locating Engine Identification - (M52/M52TU)

M54
2007 BMW 335i
Fig. 21: Locating Engine Identification - (M54)

M56
Fig. 22: Locating Engine Identification - (M56)

N40/N45
2007 BMW 335i
Fig. 23: Locating Engine Identification - (N40/N45)

N42/N46/N46T
Fig. 24: Locating Engine Identification - (N42/N46/N46T)

N51/N52/N52K/N53/N54
2007 BMW 335i
Fig. 25: Locating Engine Identification - (N51/N52/N52K/N53/N54)

N62

N73
2007 BMW 335i

S54
Fig. 28: Locating Engine Identification - (S54)

S85
2007 BMW 335i
Fig. 29: Locating Engine Identification - (S85)

W10/W11
Fig. 30: Locating Engine Identification - (W10/W11)

W17
2007 BMW 335i
Fig. 31: Locating Engine Identification - (W17)

Assemble engine.
MOUNTING ENGINE ON ASSEMBLY STAND (N54)
 00 1 450
 11 8 541
 11 8 542
damage) .
 Remove engine. (See 11 00 050 REMOVING AND INSTALLING ENGINE (N54))
Mount engine with special tool 11 8 541 to special tool 00 1 450.
Mount engine or engine block with special tool 11 8 542 to 11 8 541.

2007 BMW 335i
12 CYLINDER HEAD WITH COVER

11 12 000 REMOVING AND INSTALLING OR SEALING CYLINDER HEAD COVER (N54)
 11 8 620
 Disconnect negative battery lead.

 Remove acoustic cover.
 Remove rod-type ignition coils. (See 12 13 511 REPLACING SPARK PLUGS (N54, N53) )
 Unclip wiring harness for injectors. (See 12 51 100 REPLACING WIRING HARNESS SECTION
FOR IGNITION COIL (N54) )
 Remove injectors.
 Remove tension strut. (See 51 71 371 REMOVING AND INSTALLING/REPLACING TENSION
STRUT ON LEFT OR RIGHT SPRING STRUT DOME and/or 51 71 371 REMOVING AND
INSTALLING/REPLACING TENSION STRUT ON LEFT OR RIGHT SPRING STRUT DOME )
 Remove fresh air duct. (See 51 13 116 REMOVING AND INSTALLING COWL PANEL COVER
and/or 51 13 116 REMOVING AND INSTALLING COWL PANEL COVER )
Disconnect vacuum lines (2) from vacuum lines (1).
Unclip vacuum lines (1).

2007 BMW 335i
Fig. 33: Identifying Vacuum Lines

Disconnect vacuum lines (1) from vacuum lines (2).
Unclip vacuum line (2) and lay to one side.
Fig. 34: Identifying Vacuum Line & Lay To Side

Release screw (1) with special tool 11 8 620. (See 11 8 620 WRENCH SOCKET WAF 10 )
2007 BMW 335i
Fig. 35: Identifying Special Tool & Screw

Release screws (1) on valve cover.
Fig. 36: Identifying Screws On Valve Cover

Release screws (1 and 2).
Tightening torque, see 11 12 4AZ in ENGINE -- TORQUE SPECIFICATIONS -- TWIN TURBO

2007 BMW 335i
Fig. 37: Identifying Valve Cover & Screw

Installation:
Replace seal (1).
Press gasket (1) into valve cover.
Fig. 38: Identifying Valve Cover & Seal

Assemble engine.
11 12 100 REMOVING AND INSTALLING CYLINDER HEAD (N54)
 11 0 320
 11 4 420
 11 4 430
2007 BMW 335i
 11 4 471
 11 4 472
 11 8 580
damage) .
Fit new cylinder head screws.
Do not wash off bolt coating.
There must be no coolant, water or engine oil in the pocket holes.
Risk of corrosion and cracking!
 Remove engine. (See 11 00 050 REMOVING AND INSTALLING ENGINE (N54))

 Remove inlet and exhaust adjustment unit (See 11 36 046 REMOVING AND
INSTALLING/REPLACING INLET AND EXHAUST ADJUSTMENT UNITS (N54))
Release screws (1).
Unclip timing chain module (3) at junction (2) and remove towards top.
Set down timing chain.
IMPORTANT: If the timing chain is stowed in the gear case, the crankshaft must no longer be
rotated.
This would cause the timing chain on the crankshaft sprocket wheel to jam or
jump.
Installation:
The timing chain is lifted out with a hook only during assembly.
2007 BMW 335i
Fig. 39: Identifying Timing Chain, Junction & Screw

Release screws (1).
NOTE: Screw (2) can only be released when the timing chain module is pressed
forward slightly.
IMPORTANT: Secure bolt (2) with a gripper against falling down.
Release bolt (2).
Fig. 40: Identifying Timing Chain Module Screw

IMPORTANT: Observe different bolt heads.
Release M9 cylinder head bolts (1) with special tool 11 4 420. (See 11 4 420 TORX SOCKET T50 )
2007 BMW 335i

Release M10 cylinder head bolts (1) with special tool 11 8 580 from outside inwards. (See 11 8 580 WRENCH
SOCKET TORX T60 )
IMPORTANT: All cylinder head bolts must be replaced.
Jointing torque and angle of rotation must be observed without fail.
Risk of damage!

Shims (1) of cylinder head bolts can only be removed with a magnet (2) between cylinder head and bearing
strip.
2007 BMW 335i
Fig. 43: Identifying Shim & Magnet

Secure special tool 11 0 320 with existing cylinder head cover bolts (1). (See 11 0 320 REMOVAL AND
INSTALLATION BRACKET )
Tightening torque, see 11 12 4AZ in TORQUE SPECIFICATIONS -- TWIN TURBO
IMPORTANT: Removing and install cylinder head with a second person helping.
Weight of cylinder head with add-on parts is approx. 40 kg.
Do not set cylinder head down on sealing face, risk of damage to valves.

IMPORTANT: Set down cylinder head with inlet and exhaust camshafts on side only, risk of
damage to valves (1).
2007 BMW 335i
Fig. 45: Identifying Cylinder Head With Inlet & Exhaust Camshafts Valve
Insert special tool 11 4 430 into bores. (See 11 4 430 SEAL PLUGS (2 X) )

Remove coarse residues on sealing faces with special tool 11 4 471 from cylinder head and crankcase.
IMPORTANT: Do not use any metal-cutting tools.

2007 BMW 335i

Remove fine residues on sealing faces with special tool 11 4 472 from cylinder head and crankcase.
IMPORTANT: Do not use any metal-cutting tools.
There must be no coolant, water or engine oil in the pocket holes.
Risk of corrosion and cracking!
Clean all pocket holes.
Replace cylinder head gasket.

IMPORTANT: Observe sequence for tightening cylinder head bolts without fail.
Fit new cylinder head screws.

2007 BMW 335i
Insert cylinder head bolts (1 to 10) with special tool 11 8 580. (See 11 8 580 WRENCH SOCKET TORX
T60 )
Insert cylinder head bolts (11 to 14) with special tool 11 4 420. (See 11 4 420 TORX SOCKET T50 )
NOTE: Picture shows inlet and exhaust camshafts removed.
Fig. 49: Identifying Cylinder Head Bolts Tighten Sequence

Observe sequence for tightening cylinder head bolts without fail.
IMPORTANT: The 2nd torsion angle relates only to cylinder head bolts 1 to 10.
Installation:
 Jointing torque:
All cylinder head bolts 1 to 14 to 30 Nm
 1st angle of rotation:
All cylinder head bolts 1 to 14 to 90°
 2nd angle of rotation:
Only cylinder head bolts 1 to 10 to 90°
 3rd angle of rotation:

2007 BMW 335i
All cylinder head bolts 1 to 14 to 45°
Replace screws (1).
IMPORTANT: Secure bolt (1) with a gripper against falling down.
Fig. 50: Identifying Cylinder Head Bolts

Assemble engine.
11 12 729 CHECK CYLINDER HEAD FOR WATER LEAKS (N54)
 11 4 341
 11 4 342
 11 4 344
 11 4 345
IMPORTANT: Pressure-test cylinder head to max. 3 bar .
Heat cylinder head to 60°.
Check for bubble formation in a water bath.
 Remove cylinder head. (See 11 12 100 REMOVING AND INSTALLING CYLINDER HEAD (N54))
 Disassemble cylinder head.
2007 BMW 335i
NOTE: Observe mounting of special tool 11 4 341 on 1 cylinder.
Secure special tool 11 4 341 with bolts 11 4 345 to 25 Nm .
Fig. 51: Identifying Cylinder Head

Install special tool 11 4 341 with special tool 11 4 345.
Installation:
1 cyl is marked.

Fit special tool 11 4 342 with bolts (1), insert knurled screw in direction of arrow.
Sealing flange must rest flat.

2007 BMW 335i

Secure special tool 11 4 344 with bolts (1).
NOTE: Compressed air at valve (2) must not exceed 3 bar .
Heat cylinder head to 60°.
Check for bubble formation in a water bath.

Assemble engine.
13 OIL SUMP
11 13 000 REMOVING AND INSTALLING, SEALING OR REPLACING OIL SUMP (N54)
2007 BMW 335i
damage) .
 Remove engine splash guard.

 Secure engine in installation position. (See 11 00 670 SECURING ENGINE IN INSTALLATION
POSITION (N54))
 Lower front axle. (See 31 11 506 LOWERING/RAISING FRONT AXLE CARRIER and 31 11 506
LOWERING/RAISING FRONT AXLE CARRIER )
 Remove vane-type pump of power steering.
 AWD optional extra: Remove front axle differential.
NOTE: If automatic transmission optional extra installed, lines must be detached from
engine oil sump.
Release bolts (3) on transmission.
Detach return hose (2).
Release screws along line (1).
Installation:
Replace aluminum screws.
If necessary, release bolts (4), remove oil level sensor.
Installation:
Replace all seals.

2007 BMW 335i
Fig. 55: Identifying Return Hose, Screw & Bolts

Assemble engine.
11 13 000 REMOVING AND INSTALLING, SEALING OR REPLACING OIL SUMP (N54) AWD
damage) .

 Secure engine in installation position.
 Lower front axle.
 Remove left drive shaft.
 Remove right drive shaft.
 Remove front axle differential.
NOTE: The lines must be detached from the engine oil sump in the case of the optional
extra automatic transmission; if necessary, detach vane pump and place to one
side. Release bolts on transmission.
Release return hose.
Release screws along line (1).

2007 BMW 335i
Installation:
Replace all seals.
If necessary, release bolts (4), remove oil level sensor.
Fig. 56: Identifying Oil Level Sensor & Bolts

Assemble engine.
14 HOUSING COVER
11 14 005 REPLACING FRONT CRANKSHAFT RADIAL SEAL (N54)
 11 4 370
 11 9 221
 11 9 222
 11 9 223
 11 9 224
 11 9 231
 11 9 232
 11 9 233
 Remove vibration damper. (See 11 23 010 REMOVING AND INSTALLING OR REPLACING

VIBRATION DAMPER (N54))
2007 BMW 335i
IMPORTANT: Do not release central bolt.
If the central bolt is released, the sprocket wheels of the timing chain and the oil pump will no longer be non-
positively connected to the crankshaft. The camshafts to the crankshaft can warp (risk of damage) .
The timing must be adjusted again. (See 11 31 505 ADJUSTING CAMSHAFT TIMING (N54))
Fig. 57: Identifying Central Bolt

Turn back special tool 11 9 222.
Push special tool 11 9 221 onto crankshaft.
IMPORTANT: When screws are tightened down (special tool 11 9 224), radial seal is pressed
inwards approx. 1 mm and thus slackened for subsequent removal.
Insert screws (special tool 11 9 224) and tighten down to approx. 20 Nm.
2007 BMW 335i
Insert screws (special tool 11 9 223) and screw in until they make contact without play.
IMPORTANT: Do not overload special tool 11 9 223 (metal screws).

Remove screws (special tool 11 9 224).

Insert screw (special tool 11 9 222) carefully and slowly and withdraw radial seal (1).
2007 BMW 335i

Installation:
Clean sealing surface (1) and degrease thoroughly in area of housing partition.
Apply a light coat of oil to running surface (2) of radial shaft seal.
Fig. 62: Identifying Sealing Surface & Running Surface

NOTE: Support sleeve (1) is supplied with radial seal (2).
When radial seal (2) is installed, only support sleeve (1) may be used as a slip
sleeve.
Radial seal (2) has a groove on both left and right sides.
IMPORTANT: After installation, the grooves must be filled with sealing compound.
2007 BMW 335i
Fig. 63: Identifying Support Sleeve With Radial Seal

Attach support bushing (2) with radial shaft seal (1).
Push on radial shaft seal (1) in direction of arrow.
Fig. 64: Pushing On Radial Shaft Seal

Pay attention to opening on radial shaft seal (1) on left and right.
Remove support bushing (2).

2007 BMW 335i
Fig. 65: Identifying Radial Shaft Seal & Support Bushing

IMPORTANT: The following text describes installation and sealing between the engine block
and radial seal.
The engine block will not be leakproof at the outside of the radial seal if you fail
to comply with the individual work steps and the work sequence.
NOTE: The required parts are available from the BMW Parts Service (EPC).
Remove screw caps (1) from injector (2).
Screw on metering needle.
Insert piston for pressing out or use special tool 11 4 370. See 11 4 370 PRESSING FIXTURE
Fig. 66: Identifying Injector & Cap Screw

Fit special tool 11 9 232.

2007 BMW 335i
Coat both grooves on radial shaft seal with Loctite primer, manufacturer's number 171000, and expose to air for
approx. one minute.

Draw in radial shaft seal with special tool 11 9 231 in conjunction with special tool 11 9 233 until flush.
2007 BMW 335i
Fig. 69: Identifying Radial Shaft Seal

11 14 010 REPLACING VACUUM PUMP SEALING COVER (N54)
 11 8 531
 11 8 532
 11 8 533
 11 8 535
 11 8 544
 Remove fan cowl.

 Remove alternator drive belt. (See 11 28 010 REPLACING ALTERNATOR DRIVE BELT (N54))
 Remove both drive belt tensioners. (See 11 28 020 REPLACE ALTERNATOR DRIVE BELT
TENSIONER (N54))
NOTE: For purposes of clarity, illustrations show alternator and servo pump.
Secure special tool 11 8 531 with special tool 11 8 535.
Twist out special tool 11 8 533 in direction of arrow until special tool 11 8 532 is released from mounting.
Secure special tool 11 8 532 against falling down.

2007 BMW 335i
Position special tool 11 8 532 by hand on sealing cover.
Screw in special tool 11 8 544.
NOTE: The sealing cover is pressed out diagonally during this work step
Screw in new sealing cover (1) with special tools 11 8 532 and 11 8 533 until flush with housing.
2007 BMW 335i
Assemble engine.
11 14 151 REPLACING CRANKSHAFT RADIAL SEAL (N54)
 11 9 181
 11 9 182
 11 9 183
 11 9 184
 11 9 200
 Remove flywheel. (See 11 22 500 REMOVING AND INSTALLING OR REPLACING
FLYWHEEL (N54))
NOTE: Radial seal has six removal openings for removal with special tool 11 9 200.
(See 11 9 200 PULLER )
2007 BMW 335i

NOTE: If necessary, remove rubber coating (1) on top side of radial seal and expose a
removal opening (2) (see Fig. 74).
Fig. 74: Identifying Rubber Coating & Radial Seal

Fit special tool 11 9 200. Insert metal screws into removal opening of radial seal and initially tighten without
play (do not overtighten metal screws). (See 11 9 200 PULLER )
Screw in spindle (1) slowly and carefully and detach radial seal.
2007 BMW 335i
Fig. 75: Identifying Special Tool (11 9 200) With Screw

Installation:
Clean sealing surface (1) and degrease thoroughly in area of housing partition.
Apply a light coat of oil to running surface (2) of radial shaft seal.
Fig. 76: Identifying Area Sealing Surface

NOTE: Support sleeve (4) is supplied with radial shaft seal (1).
When radial shaft seal (1) is installed, only support sleeve (4) may be used as a
slip sleeve.
Radial shaft seal (1) has a groove (2) on both left and right sides.
IMPORTANT: After installation, grooves (2) must be filled with sealing compound.
2007 BMW 335i
Fig. 77: Identifying Radial Shaft Seal In Groove On Both Left & Right Sides
IMPORTANT: The seal between the engine block and radial seal is described below.
The engine block will not be leakproof at the outside of the radial seal if you fail
to comply with the individual work steps and the work sequence.
NOTE: The required parts are available from the BMW Parts Service (ETK).
Remove screw caps (1) from injector (2).
Screw on metering needle.
Insert piston for pressing out.
Injector (2) contains the sealing compound Loctite, manufacturer's number 193140.
Bottle (3) contains the primer Loctite, manufacturer's number 171000.
Fig. 78: Identifying Injector, Screw Caps & Bottle

2007 BMW 335i
Installation:
Fit support sleeve (4) with radial shaft seal (1) on crankshaft.
Align groove (2) centrally to housing partition (3).
Coat both grooves (2) on radial shaft seal (1) with Loctite primer, manufacturer's number 171000, and expose to
air for approx. one minute.
Push radial shaft seal (1) by hand as far as possible onto running surface.
Carefully remove support sleeve (4).
Fig. 79: Identifying Support Sleeve & Housing Partition

NOTE: Spacer ring (1) is supplied with radial shaft seal.
Screw special tool 11 9 182 with screws (special tool 11 9 184) to crankshaft.
Fit spacer ring (1) on preassembled radial shaft seal.

2007 BMW 335i
Fig. 80: Identifying Special Tool (11 9 182, 11 9 184) With Screws To Crankshaft
Draw in radial shaft seal and spacer ring with special tool 11 9 181 in conjunction with special tool 11 9 183.
Then remove spacer ring again.
Fig. 81: Identifying Special Tool (11 9 181 & 11 9 183)

Before filling with sealing compound:
Insert brush with Loctite primer, manufacturer's number 171000, as far as possible into grooves (1) on radial
shaft seal and coat housing partition on engine block.
2007 BMW 335i
Fig. 82: Identifying Brush With Primer

Fill both grooves (1) flush with Loctite sealing compound, manufacturer's number 193140.
Fig. 83: Identifying Sealing Area

Coat surface of sealing compound in both grooves (1) with Loctite primer, manufacturer's number 171000.
NOTE: Loctite primer, manufacturer's number 171000, binds the Loctite sealing
compound, manufacturer's number 193140, and prevents leakage.
2007 BMW 335i
Fig. 84: Identifying Area Applying Sealing

Assemble engine.
21 CRANKSHAFT WITH BEARING

11 21 531 REPLACING ALL CRANKSHAFT MAIN BEARINGS (N54)
 00 2 590
 11 4 470
 11 8 510
damage) .
 Remove crankshaft.
Check setting of oil spray nozzles, adjusting if necessary:
Attach special tool 11 8 510 to bolt connection on main bearing, secure with bolt (1). (See 11 8 510 GAUGE )
Installation:
2007 BMW 335i
Oil nozzle must be located precisely in groove of special tool 11 8 510; adjust if necessary. (See 11 8 510
GAUGE )
Fig. 85: Identifying Special Tool (11 8 510) On Main Bearing

Adjust oil nozzle.
Release screw (1).

Remove bearing shells (2) and (3).
NOTE: Guide bearing shell (3) is a thrust bearing.
Observe bearing classification. (See 11 21 CRANKSHAFT AND BEARINGS N54

B30 )
2007 BMW 335i
Fig. 87: Identifying Bearing Shells

Installation:
Bearing shell (1) with lubricant groove must be fitted in crankcase upper section.
Bearing shell (2) without lubricant groove must be fitted in crankcase lower section (bed plate).
Fig. 88: Locating Bearing Shell

Bearing classification (1) of crankshaft as per table (values 1 to 3).
Bearing classification (2) of connecting rods as per table (values b and r). (See 11 24 571 REPLACING ALL
CONNECTING ROD BEARINGS (N54))
2007 BMW 335i
Fig. 89: Locating Bearing Classification Of Connecting Rods

Bearing classification (1) in crankcase as per table (values of A/B/C).
Installation:
When all the letters and number code have been determined, the bearing shell color must be allocated, see
COLOR COMBINATIONS TABLE.
IMPORTANT: Engine damage will result if an insufficiently small bearing play is determined.
The color combination Yellow and Red must not be fitted. Possible color
combinations, see COLOR COMBINATIONS TABLE.
Fig. 90: Locating Bearing Classification Of Crankshaft

COLOR COMBINATIONS TABLE

(A1) Bedplate/Yellow (B1) Bedplate/Yellow (C1) Bedplate/Green
(A1) Crankcase/Yellow (B1) Crankcase/Green (C1) Crankcase/Green
2007 BMW 335i
(A2) Bedplate/Green (B2) Bedplate/Green (C2) Bedplate/Green

(A2) Crankcase/Yellow (B2) Crankcase/Green (C2) Crankcase/Red
(A3) Bedplate/Green (B3) Bedplate/Red (C3) Bedplate/Red
(A3) Crankcase/Green (B3) Crankcase/Green (C3) Crankcase/Red
Insert all bearing shells (2 and 3).
IMPORTANT: Clean sealing surfaces.
Do not clean sealing faces with a metal-cutting tool.
Clean sealing faces with special tool 11 4 470 only. (See 11 4 470 CLEANING KIT )
Determine bearing play with special tool 00 2 590.
Installation:
All measuring points must be free from oil and grease.
Use used screws to determine bearing play.
Set up crankcase lower section with bearing shells.
Fig. 91: Identifying Crankshaft Bearing Shells

Remove lower crankcase.
Read off bearing play at width of flattened plastic thread and measurement scale.
Crankshaft bearing clearance radial.
Installation:
2007 BMW 335i
Remove plastic thread.
Apply a light coat of oil to bearing shells and crankshaft.
Fig. 92: Locating Bearing Shells & Crankshaft

Install crankcase lower section.
Assemble engine.
22 FLYWHEEL
11 22 500 REMOVING AND INSTALLING OR REPLACING FLYWHEEL (N54)
 11 4 180
 11 9 260
 Remove clutch.
Enlarge special tool 11 9 260 with an elongated hole. (See 11 9 260 COUNTER SUPPORT WITH SCREW
CONNECTION )
Work out elongated hole on special tool 11 9 260 to 8 mm . (See 11 9 260 COUNTER SUPPORT WITH
SCREW CONNECTION )
2007 BMW 335i
Fig. 93: Identifying Special Tool (11 9 260) With Elongated Hole
Manual transmission:
Block flywheel with special tool 11 9 260. (See 11 9 260 COUNTER SUPPORT WITH SCREW
CONNECTION )
Release flywheel screws with special tool 11 4 180. (See 11 4 180 SCREWDRIVER SOCKET TORX T60 )
Installation:
Flywheel is secured with a dowel pin.
Fit new flywheel screws.
Fig. 94: Identifying Special Tool (11 9 260 & 11 4 180)

Automatic transmission:
2007 BMW 335i
Block flywheel with special tool 11 9 260. (See 11 9 260 COUNTER SUPPORT WITH SCREW
CONNECTION )
Release flywheel bolts with tool (1).
Installation:
Flywheel is secured with a dowel pin.
Fit new flywheel screws.
Fig. 95: Identifying Special Tool (11 9 260) On Flywheel

Assemble engine.
11 22 513 REPLACING ROLLER BEARING FOR DUAL-MASS FLYWHEEL
 23 4 031
 23 4 033
 23 4 035
 23 4 036
 23 4 040
 Transmission removed.
 Remove clutch release bearing
2007 BMW 335i
Pressing out roller bearing:
Install special tool 23 4 031 in front of drive shaft spline teeth.
Screw in grease spindle 23 4 033 completely.
Brass tip must immerse fully into roller bearing.
Press in grease with grease gun 23 4 040 until roller bearing is disengaged from drive shaft. See 23 4 040
GREASE GUN
Fig. 96: Identifying Special Tool (23 4 031) On Front Of Drive Shaft Spline Teeth
Remove special tool 23 4 031.
Remove pressed-in grease (1) from drive shaft completely.
Then reinstall special tool.

2007 BMW 335i
Pressing in roller bearing:
Slide in pressure spindle 23 4 035.
Attach thrust piece 23 4 036 to pressure spindle.
Push roller bearing (1) onto thrust piece.
Fig. 98: Pushing Roller Bearing Onto Thrust Piece

Screw in pressure spindle (1) until roller bearing is fully pressed in.
Fig. 99: Identifying Pressure Spindle

23 VIBRATION DAMPER
11 23 010 REMOVING AND INSTALLING OR REPLACING VIBRATION DAMPER (N54)

2007 BMW 335i
 Detach front underbody protection.

 Remove drive belt.
Release screws (1).
Remove vibration damper (2).
Fig. 100: Identifying Vibration Damper With Screws

Assemble engine.
24 CONNECTING ROD WITH BEARING

11 24 571 REPLACING ALL CONNECTING ROD BEARINGS (N54)
 00 2 590
 00 9 120
IMPORTANT: All crank pins are connected with the crankshaft.
Blue/Red bearing shell colors are no longer used in combination.
 Remove all pistons.
IMPORTANT: All crankshaft crank pins are classified.

2007 BMW 335i
Bearing shell colors are different in connecting rod and in connecting rod
bearing cap.
Possible classifications per connecting rod at top and bottom:
r: Connecting rod = Yellow.
Connecting rod bearing cap = Red.
b: Connecting rod = Violet.
Connecting rod bearing cap = Blue.
Only one color may be fitted per connecting rod and connecting rod bearing cap.
In direction of arrow from (1 to 2) crank pin (1 to 6).
Example:
Possible classification: rbbrrb.
Fig. 101: Identifying Connecting Rod Bearing Cap

Cyl. 1: Classification r = rod side Yellow bearing cap side Red.
Cyl. 2: Classification b = rod side Violet bearing cap side Blue.

2007 BMW 335i
Install new conrod bearing shells.
In each case insert only one color of bearing shell (1 and 2) for each conrod.
Fig. 102: Identifying Connecting Rod Bearing Shell

Check conrod bearing clearance.
Piston in BDC position.
Fit special tool 00 2 590 (Plastigage Type PG 1) to oil-free crankshaft.
Fit bearing cap so that pairing letters match up.
Fig. 103: Locating Plastigage Type

IMPORTANT: Do not distort conrods or crankshaft.

2007 BMW 335i
Use the old conrod bolts to check conrod clearance.
Tighten down conrod bolts with special tool 00 9 120.

Remove bearing cap. Read off bearing clearance at width of crushed plastic thread with aid of measuring scale.
Conrod bearing clearance.
 Remove plastic thread.

 Coat crankshaft and bearing shells with oil.
 Install new conrod bolts and tighten down with special tool 00 9 120.
Fig. 105: Locating Bearing Shells

2007 BMW 335i
Assemble engine.
25 PISTON WITH RINGS AND PIN

11 25 530 REMOVING AND INSTALLING/REPLACING ALL PISTONS (N54)
 00 9 120
 11 5 464
 11 8 141
 11 8 560
 11 8 561
 11 8 562
 11 8 563
 11 8 590
WARNING: Protective goggles must be worn when working on the piston pin circlip.
IMPORTANT: If pistons, conrods and bearing shells are reused, they must be reinstalled in
the same places.
Individual conrod replacement is not permitted; they are classified according to

weight categories.
Conrods and conrod bearing caps are denoted with the same pairing letters;
mixing them up will result in engine damage.
Piston and piston pins are paired and must not be fitted individually.
 Remove engine.
 Mount engine on assembly stand.
 Remove intake air manifold.
 Remove cylinder head.
 Remove engine oil sump.
 Remove oil pump.
NOTE: In event of heavy oil carbon residue:

2007 BMW 335i
Carefully remove oil carbon residue from cylinder wall.
NOTE: Illustrations show N46.
Fig. 106: Locating Cylinder Oil Carbon

Do not release screw (1).
Oil spray nozzle (2) must not be maladjusted or bent.
If necessary, readjust (risk of damage).
Fig. 107: Locating Oil Spray Nozzle & Screw

Release conrod bolts (1).
Remove conrod bearing cap (2) in direction of arrow.

2007 BMW 335i
IMPORTANT: Conrods and conrod bearing caps are denoted with the same pairing letters;
mixing them up will result in engine damage.
Fig. 108: Identifying Bearing Cap & Bolts

Screw special tool 11 8 590 into conrod big end. See 11 8 590 INSERTION TOOL
Press out conrod and piston to cylinder head side.
IMPORTANT: Risk of damage to oil spray nozzle.
Fig. 109: Identifying Special Tool (11 8 590) Into Conrod Big
Preliminary work:
Clamp special tool 11 8 561 in a vice.
Secure piston (1) with conrod to special tool 11 8 561.

2007 BMW 335i
Fig. 110: Identifying Special Tool (11 8 561) With Piston

WARNING: Protective goggles must be worn for the next work step.
Protective goggles must be worn.
To lever out piston circlip (1), support special tool 11 5 464 on piston (2).
Lever out piston circlip (1) with special tool 11 5 464 in direction of arrow.
Fig. 111: Identifying Special Tool (11 5 464) With Piston Circlip
If necessary, replace connecting rods.
IMPORTANT: Connecting rods are divided into weight categories and are only available as a
set.
Old and new connecting rods must not be installed in mixed combinations.
2007 BMW 335i
Installation:
The piston pin must be able to be pressed through the liner by hand with little force and must not display any
significant play.
Fig. 112: Identifying Piston Pin

Measure piston installation clearance:
Measure piston diameter with micrometer at measuring point A from bottom edge of piston and offset at 90° to
the axis of the piston pin.
Piston diameter at measuring point A.
Fig. 113: Identifying Piston Diameter Measuring Point

Adjust micrometer to cylinder bore of engine block. Set internal caliper on micrometer to zero. Measure
bottom, center and top of cylinder bore in direction of travel and direction of engine rotation.
Diameter of cylinder bore.
Piston installation clearance.
Total permissible wear tolerance.

2007 BMW 335i
If necessary, replace piston.
Fig. 114: Identifying Diameter Of Cylinder Bore

WARNING: Protective goggles must be worn.
IMPORTANT: The opening of the piston pin circlip must be installed in the 6 o'clock position
on the piston - risk of damage .
Insert piston circlip (2) into groove of special tool 11 8 562.
Bring piston circlip (2) into assembly position (1).
Fig. 115: Inserting Piston Circlip Into Groove Of Special Tool (11 8 562)

2007 BMW 335i
Slide special tool 11 8 563 up to piston pin circlip (2)
Special tools 11 8 562 and 11 8 563 are prepared.
Fig. 116: Identifying Special Tools (11 8 562 & 11 8 563)

Cutout on special tool 11 8 562 must point to piston crown; only then can special tool 11 8 563 be correctly
fitted.
When special tools 11 8 562 and 11 8 563 are correctly positioned, the piston pin circlip must be driven in with
a plastic hammer in the direction of the arrow.
NOTE: See Fig. 117 .
Fig. 117: Identifying Special Tool (11 8 562) To Piston Crown

2007 BMW 335i
Piston pin circlip is correctly installed when opening (1) points downwards.
Fig. 118: Locating Piston Pin Circlip

NOTE: B 30.
Install all piston rings.
Install all bearing shells.
Coat piston and piston rings with oil.
Pre-install piston (2) in special tool 11 8 141.
Screw on special tool 11 8 590 in connecting rod (2). See 11 8 590 INSERTION TOOL
Installation:
Check protective lugs (1) on special tool 11 8 590 for correct position and damage. See 11 8 590 INSERTION
TOOL
2007 BMW 335i
Fig. 119: Identifying Piston In Special Tool (11 8 141)

Insert piston with conrod in cylinder.
IMPORTANT: Risk of damage to oil spray nozzle.
Danger of piston ring failure.
Press in piston in direction of arrow with finger pressure only, do not drive in.
Insert piston so that arrow on piston crown points to camshaft drive.
Press in piston (1) with special tool 11 8 141.
Fig. 120: Identifying Piston In Special Tool (11 8 141)

IMPORTANT: Conrod and conrod bearing cap are identified with pairing letters (1) and must
not be mixed up.
Mixing them up or incorrectly fitting the conrod bearing cap on the big end will
result in engine damage.
2007 BMW 335i
Fig. 121: Identifying Mark On Bearing Cap

Apply a light coat of oil to crank pin.
Assemble conrod and crank pin.
Screw off special tool 11 8 560 in counterclockwise direction. See 11 8 560 REMOVAL AND
INSTALLATION KIT
Fig. 122: Identifying Special Tool (11 8 560) On Crank Pin

Fit bearing caps (2) so that pairing letters match up.
Install new conrod bolts (1).

2007 BMW 335i
Fig. 123: Identifying Bearing Caps & Bolts

Adjust torsion angle of conrod with special tool 00 9 120 (see Fig. 124 ).

Assemble engine.
11 25 671 REPLACING PISTON RINGS ON ALL PISTONS (N54)
 Remove all pistons.
Measuring axial clearance of piston rings in piston ring groove.
Technical Data.
2007 BMW 335i
NOTE: It is not possible to measure the axial clearance of the oil scraper rings.
Fig. 125: Identifying Clearance Of Piston Rings In Piston Ring Groove

Remove compression ring and stepped ring upwards with piston ring pliers.
Oil scraper ring comprises two steel band rings and a support spring.
NOTE: Oil scraper ring cannot be removed with piston ring pliers.
Put aside piston rings in correct sequence and installation position.
Fig. 126: Removing Piston Ring

Installation:
New pistons may only be installed together with new piston rings.
Determine gap with a feeler gauge.

2007 BMW 335i
Fig. 127: Identifying Piston Rings Gap

NOTE: Schematic representation of piston rings.
Installation:
Piston rings with "TOP" identification must point to piston crown.
1. Plain compression ring

2. Stepped compression ring "Top"
3. Two-part oil scraper ring
Fig. 128: Identifying Plain Compression Ring, Compression Ring & Oil Scraper Ring
NOTE: Oil control ring comprises two steel band rings (1) and a support spring (2).
Installation:
Insert support spring (2) into piston ring groove and then fit steel band rings (1) so that contact points are offset
by approx. 120°.
2007 BMW 335i
Fig. 129: Identifying Support Spring & Steel Band Rings

Offset the contact points (1) of the piston rings by approx. 120° to each other but do not position above the
piston pin boss.
NOTE: See N52.
Fig. 130: Identifying Contact Points Of Piston Rings

Assemble engine.
28 V-RIBBED BELT WITH TENS DEFLECT ELEMENT

11 28 010 REPLACING ALTERNATOR DRIVE BELT (N54)
 11 3 340
IMPORTANT: Mark the direction of rotation of the drive belt if it is to be reused.

2007 BMW 335i
 Remove fan cowl.
Unfasten hose clip (1).
Release quick-connect fastener (3) 90° on boost pressure pipe in direction of arrow.
Pull off air hose (2).
Installation:
Bring lock (3) back 90° into installation position.
Recirculated air hose must audibly snap into place.
Fig. 131: Identifying Air Hose Installation Position

Unclip line (1) from holder (2) in direction of arrow.
Fig. 132: Identifying Air Hose Holder

2007 BMW 335i
Release coolant hose (1) from holder (2).
Fig. 133: Identifying Coolant Hose & Holder

Release screw (1).
Fold air duct (2) down.
NOTE: Do not remove air duct (2).
Fig. 134: Identifying Air Duct With Screw

Turn belt tensioner (1) in direction of arrow until bore is flush on housing.
Secure belt tensioner in place with special tool 11 3 340. See 11 3 340 LOCKING PIN (2)
2007 BMW 335i
Fig. 135: Identifying Belt Tensioner With Special Tool (11 3 340)
Remove drive belt (1).
Installation:
Mark the direction of rotation of the drive belt if it is to be reused.
Fig. 136: Identifying Drive Belt

Pretension tensioning pulley (1) in direction of arrow.
Remove special tool 11 3 340. See 11 3 340 LOCKING PIN (2)

2007 BMW 335i
Fig. 137: Identifying Tensioning Pulley

Installation:
Note arrangement of drive belt
Fig. 138: Identifying Drive Belt Installation Position

Assemble engine.
Installation:
Check that drive belt for is in correct installation position - risk of damage.
11 28 020 REPLACE ALTERNATOR DRIVE BELT TENSIONER (N54)
 11 3 340
2007 BMW 335i
Remove special tool 11 3 340. See 11 3 340 LOCKING PIN (2)
Release screw on belt tensioner.
Fig. 139: Identifying Drive Belt Screw And Belt Routing

Assemble engine.
31 CAMSHAFT
11 31 005 CHECKING CAMSHAFT TIMING (N54)
 11 0 300
 11 4 281
 11 4 283
 Remove cylinder head cover.

 Remove front splash guard.
Remove fastener (1) in direction of arrow.
Installation:
2007 BMW 335i
Install fastener (1) with bore facing outwards.
Fig. 140: Removing Fastener

Rotate crankshaft at central bolt into TDC position.
Slide in special tool 11 0 300 in direction of arrow and block crankshaft. See 11 0 300 PLUG MANDREL
IMPORTANT: On engines with automatic transmissions, there is shortly before the special
tool bore for the TDC position a large bore which can be confused with the
special tool bore.
If the flywheel is secured in the correct bore with special tool 11 0 300, the engine can no longer be moved at
the central bolt. See 11 0 300 PLUG MANDREL
Fig. 141: Sliding In Special Tool (11 0 300)

With 1st cylinder in firing TDC position, cams of inlet camshaft (1) at 6th cylinder point downwards at an
angle.
2007 BMW 335i
With 1st cylinder in firing TDC position, cams of exhaust camshaft (2) at 6th cylinder point downwards at an
angle.
Roller cam follower is not actuated.
NOTE: If the timing is checked while the engine is installed, the position of the
camshaft can only be checked with a mirror.
Fig. 142: Identifying 1st Cylinder In Firing TDC Position

Secure special tool 11 4 283 on cylinder head with screws (1).
Mount special tool 11 4 281 on inlet and exhaust camshafts.
If special tools 11 4 281 cannot be attached, the timing must be adjusted.
Fig. 143: Identifying Special Tool (11 4 283) On Cylinder Head

Remove all special tools.

2007 BMW 335i
Assemble engine.
11 31 025 REMOVING AND INSTALLING OR REPLACING INTAKE CAMSHAFT (N54)
 00 9 120
 11 4 350
 11 5 553
 11 8 550
 11 8 551
 11 8 552
 11 8 553
 11 9 000
IMPORTANT: It is absolutely essential to follow an exact procedure for removing and

installing the exhaust camshaft.
Risk of damage!
The upper and lower bearing banks must be tensioned with a total of six
special tools 11 8 553.
Special tool 11 8 550 can be used for intake and exhaust sides. See 11 8 550
LOCATING FIXTURE

 Remove intake adjustment unit of intake camshaft
Release bearing cap screw connections from outside inwards.
Lift out lower and upper bearing banks (1) with camshaft.
NOTE: Illustration shows N52.

2007 BMW 335i
Fig. 144: Identifying Lower & Upper Bearing Banks

Remove upper bearing shell.
Remove intake camshaft (1) marked with (E).
Fig. 145: Identifying Mark On Intake Camshaft

IMPORTANT: Both camshafts have different identifications.
Mixing up the two camshafts will result in engine damage.
A Exhaust camshaft.
E Intake camshaft
2007 BMW 335i
Fig. 146: Identifying Camshafts Identifications Mark

Check plain compression rings (1) for damage and replace if necessary.
Plain compression rings (1) are engaged at joint.
Press plain compression rings (1) apart upwards and downwards and removed towards front.
IMPORTANT: Plain compression rings (1) can easily break.
Fig. 147: Identifying Plain Compression Rings

IMPORTANT: Removal on engine:
Set engine to ignition TDC at cylinder No. 1.
Removed cylinder head:
When using special tool 11 9 000, it will be necessary to remove the aluminum
2007 BMW 335i
profile insert. See 11 9 000 CYLINDER HEAD EXPANDER TOOL
Installing camshaft bearing bank:
Pre-install special tool 11 8 551 on cylinders 2 and 3.
Insert special tool 11 8 552 in screw connection of cylinder head cover.
Special tool 11 8 551 is marked with letters E and A.
E = intake side.
A = exhaust side.
Press down roller cam followers on 3rd cylinder with spindle nut (2) of special tool 11 8 551.
Fig. 148: Identifying Special Tool (11 8 552) In Cylinder Head Cover
Installation:
Before installing intake camshaft, make sure roller cam follower is correctly seated on HVCA element and
valve.
2007 BMW 335i
Fig. 149: Identifying Sure Roller Cam Follower

Installation:
Pre-install bearing strip of intake camshaft.
Lubricate all bearing points in lower bearing strip with engine oil.
Installation:
Lay intake camshaft (1) in bearing strip.

Rotate intake camshaft (1) at cylinder No. 1 into position (2).

2007 BMW 335i
Fig. 151: Identifying Intake Camshaft Cylinder No. 1 Into Position

Installation:
Lower and upper bearing banks must be aligned to each other at ground surfaces (1 and 2).
Bring thrust piece and legs of special tool 11 8 553 into contact at milled surfaces.
Fig. 152: Identifying Bearing Ground Surfaces

NOTE: Schematic depiction of special tool 11 8 553 at lower bearing bank (1) and upper
bearing bank (2).
IMPORTANT: Tighten screw (3) on thrust piece to 2 Nm.

2007 BMW 335i

Position special tool 11 8 553 over screw connection of bearing banks.
Make sure that legs come into exact contact on ground surfaces, lower bearing bank (1) and upper bearing bank
(2).
Fig. 154: Identifying Special Tool (11 8 553) Installation Position

Initially tighten screw of special tool 11 5 553 to ground surfaces of lower bearing bank (1) and upper bearing
bank (2).
IMPORTANT: Tighten screws on thrust piece to 2 Nm.

2007 BMW 335i
Fig. 155: Identifying Lower Bearing Bank & Upper Bearing Bank
IMPORTANT: Set special tool 11 4 350 to 2 Nm. See 11 4 350 TORQUE WRENCH
Pretension all special tools 11 8 553 with special tool 11 4 350 only. See 11 4 350 TORQUE WRENCH

Install upper and lower bearing strips (1).
Pre-install all special tools 11 8 553.
IMPORTANT: Secure special tool 11 8 553 to MAX 2 Nm .

2007 BMW 335i
Fig. 157: Identifying Special Tools (11 8 553) With Upper & Lower Bearing Strips
Install intake camshaft with bearing strips (1) on cylinder head.
Fig. 158: Identifying Intake Camshaft With Bearing Strips

Check position of intake camshaft (1) at 6th cylinder.
Roller cam follower (2) is not actuated.

2007 BMW 335i
Fig. 159: Positioning Intake Camshaft 6th Cylinder

Tighten lower and upper bearing banks with special tool 00 9 120.
IMPORTANT: Remove special tool 11 8 553 only when camshaft screw connection is
completed .
Fig. 160: Tightening Lower & Upper Bearing Banks With Special Tool (00 9 120)
Adjust valve timing.
Assemble engine.

2007 BMW 335i
 00 9 120
 11 4 350
 11 5 553
 11 8 550
 11 8 551
 11 8 552
 11 8 553
 11 9 000

Risk of damage!
LOCATING FIXTURE


2007 BMW 335i


Mixing up the two camshafts will result in engine damage .
A Exhaust camshaft.
E Intake camshaft

2007 BMW 335i

E = intake side.
A = exhaust side.
2007 BMW 335i
Fig. 165: Identifying Special Tool (11 8 551) With Letters E & A
Installation:
valve.

Installation:
Installation:

2007 BMW 335i


Installation:
2007 BMW 335i

bearing bank (2).

(2).
2007 BMW 335i

bank (2).
IMPORTANT: Set special tool 11 4 350 to 2 Nm. See 11 4 350 TORQUE WRENCH
Pretension all special tools 11 8 553 with special tool 11 4 350 only. See 11 4
350 TORQUE WRENCH
2007 BMW 335i

IMPORTANT: Secure special tool 11 8 553 to MAX 2 Nm .

2007 BMW 335i


completed .
2007 BMW 335i
Assemble engine.
 00 9 120
 11 4 350
 11 5 553
 11 8 550
 11 8 551
 11 8 552
 11 8 553
 11 9 000

Risk of damage!
LOCATING FIXTURE

2007 BMW 335i




2007 BMW 335i
Mixing up the two camshafts will result in engine damage.
A Exhaust camshaft.
E Intake camshaft



2007 BMW 335i
E = intake side.
A = exhaust side.
Fig. 182: Identifying Special Tool (11 8 551) With Letters E & A
Installation:
valve.
2007 BMW 335i

Installation:
Installation:


2007 BMW 335i

Installation:

bearing bank (2).

2007 BMW 335i

(2).

bank (2).

2007 BMW 335i
IMPORTANT: Set special tool 11 4 350 to 2 Nm.
Pretension all special tools 11 8 553 with special tool 11 4 350 only.

IMPORTANT: Secure special tool 11 8 553 to MAX 2 Nm.

2007 BMW 335i


2007 BMW 335i

completed .
Assemble engine.
11 31 090 INSTALLING AND REMOVING/REPLACING CHAIN TENSIONER PISTON (N54)
Release chain tensioner (1).

2007 BMW 335i
IMPORTANT: Have a cleaning cloth ready. A small quantity of engine oil will emerge after the
screw connection has been released.
Make sure no oil runs onto the belt drive.
Installation:
No sealing ring is fitted during series-production assembly.
A sealing ring must be fitted by service personnel when the chain tensioner is fitted.
Fig. 195: Identifying Chain Tensioner

If the chain tensioner is reused, its oil chamber must be drained. Place chain tensioner on a level working
surface and slowly compress.
Repeat procedure twice.
Fig. 196: Placing Chain Tensioner

2007 BMW 335i
Assemble engine.
11 31 505 ADJUSTING CAMSHAFT TIMING (N54)
 00 9 120
 00 9 250
 11 0 300
 11 4 281
 11 4 283
 11 8 520
 11 9 340
To open the central bolt at the camshaft, grip hexagon on rear of camshaft.
Installation:
Install fastener (1) with bore facing outwards.

Rotate crankshaft at central bolt into TDC position.

2007 BMW 335i
Slide in special tool 11 0 300 in direction of arrow and block crankshaft. See 11 0 300 PLUG MANDREL
IMPORTANT: On engines with automatic transmissions, there is shortly before the special
tool bore for the TDC position a large bore which can be confused with the
special tool bore.
If the flywheel is secured in the correct bore with special tool 11 0 300, the engine can no longer be moved at
the central bolt. See 11 0 300 PLUG MANDREL

Fit special tool 11 4 283 with screws (1).
Fit special tool 11 4 281 on special tool 11 4 283.
IMPORTANT: If the special tool 11 4 281 cannot be installed, the camshaft must be rotated at
the hexagon head at the rear.

2007 BMW 335i
With 1st cylinder in firing TDC position, cams of exhaust camshaft (2) and inlet camshaft (1) at 6th cylinder
point downwards at an angle.
NOTE: If the timing is checked while the engine is installed, the position of the
camshaft can only be checked with a mirror.

Release central bolt (1) of exhaust camshaft.
Installation:
Replace screw (1).
Release central bolt (2) of inlet camshaft.
Installation:
Replace screw (2).

2007 BMW 335i
Fig. 201: Identifying Inlet & Exhaust Camshaft Bolts

Rotate sensor gears until locating pins on special tool 11 8 520 match up. See 11 8 520 GAUGE WITH
SCREWS
Push special tool 11 8 520 onto cylinder head. See 11 8 520 GAUGE WITH SCREWS
Secure special tool 11 8 520 with bolts (1 and 2). See 11 8 520 GAUGE WITH SCREWS
NOTE: Bolts (1 and 2) M6x45 with captive shim.
Fig. 202: Identifying Special Tool (11 8 520) Onto Cylinder Head
Remove chain tensioner (1).
Screw special tool 11 9 340 into cylinder head. See 11 9 340 CHAIN TENSIONER, COMPLETE
Pretension timing chain with special tool 00 9 250 to 0.6 Nm.

2007 BMW 335i
Tighten central bolts (2 and 3) with special tool 00 9 120.
Fig. 203: Identifying Central Bolts

Assemble engine.
33 ROCKER ARM WITH BEARING

11 33 050 REMOVING AND INSTALLING/REPLACING ALL CAM FOLLOWERS (N54)
 11 4 480
IMPORTANT: Rocker arms (1) are divided into bearing categories.
The tolerance classes are identified in numbers from 1 to 6.
Already used rocker arms (1) may only be reused in the same position.
A classification is not necessary in the N54 engine; in the event of replacement,

all numbers from 1 to 6 can alternatively be installed.

 Remove inlet camshaft.
 Remove exhaust camshaft.
2007 BMW 335i
Detach roller cam followers (1) from HVCA element and remove.
Set down roller cam followers in tidy and orderly fashion; if necessary, set down in special tool 11 4 480. See
11 4 480 PLACEMENT BOARDS (2X)
Installation:
Before installing exhaust and inlet camshafts, make sure roller cam followers are correctly seated.

Remove HVCA element in direction of arrow.
Installation:
If the HVCA elements are to be reused, set them down if necessary in special tool 11 4 480 in a tidy and orderly
fashion with the roller cam followers. See 11 4 480 PLACEMENT BOARDS (2X)
Fig. 205: Removing HVCA Element

2007 BMW 335i
Assemble engine.
34 VALVES WITH SPRINGS

11 34 552 REMOVING AND INSTALLING OR REPLACING ALL VALVES (N54)
 11 4 480

 Remove roller cam follower.
 Remove valve springs.
 Remove valve stem seals.
Arrangement:
1. Valve
2. Valve stem seal with spring plate, bottom
3. Valve spring
4. Top plate spring
5. Valve tapers
If the valves are to be reused, set then down in special tool 11 4 480 in a tidy and orderly fashion. See 11 4 480
PLACEMENT BOARDS (2X)
Fig. 206: Identifying Valve Arrangement Position

2007 BMW 335i
Assemble engine.
11 34 560 REPLACING ALL VALVE STEM SEALS (N54)
 11 1 480
 11 6 380

 Remove all valve springs.
Firmly press special tool 11 1 480 onto old valve stem seals. See 11 1 480 PLIERS
Detach valve stem seal from valve stem by turning and simultaneously pulling special tool 11 1 480. See 11 1
480 PLIERS
Installation:
Insert all valves.

2007 BMW 335i
Fig. 207: Identifying Special Tool (11 1 480) Onto Old Valve Stem Seals
NOTE: For use on the N54 engine, special tool 11 6 380 must be remachined according
to the sketch with a 10 mm dia. drill bit to a depth of B = approx. 23 mm. See 11
6 380 BUSH
This modification has already been taken into account for reordering.
Fig. 208: Identifying Special Tool (11 6 380) Dimension

2007 BMW 335i
IMPORTANT: Different diameters at valve stem.
All valve stem seals are color-coded.
Valve dia. 5 mm: valve stem seal is red or brown.
Valve dia. 6 mm: valve stem seal is green or light green.
Fig. 209: Identifying Valve Stem Seals Color-Coded

Installation:
Fit the mounting sleeves (plastic sleeves) supplied in the spare part on the valve stem end
Lubricate mounting sleeve.
Press on valve stem seal by hand with special tool 11 6 380 as far as it will go. See 11 6 380 BUSH
NOTE: Illustrations show N46.

2007 BMW 335i
Fig. 210: Identifying Special Tool (11 6 380) On Valve Stem Seal
Assemble engine.
11 34 715 REPLACING ALL VALVE SPRINGS (N54)
 11 0 009
 11 0 346
 11 4 480
 11 9 000
 11 9 017
IMPORTANT: Different valve stem diameters.
Mixing up the valve springs will result in damage to the engine.

 Remove intake camshaft.
Inlet valves:
Place cylinder head on special tool 11 9 000. See 11 9 000 CYLINDER HEAD EXPANDER TOOL
Press valve spring down on spring retainer with special tools 11 0 009 and 11 9 017.
2007 BMW 335i

Exhaust valves:
Place cylinder head on special tool 11 9 000. See 11 9 000 CYLINDER HEAD EXPANDER TOOL
Press valve spring down on spring retainer with special tools 11 0 009 and 11 0 346.
Fig. 212: Identifying Special Tools (11 0 009 & 11 0 346) On Spring Retainer
Remove valve tapers with a magnet.
Remove valve spring and spring retainer.
Set down on special tool 11 4 480 in a tidy and orderly fashion. See 11 4 480 PLACEMENT BOARDS (2X)
2007 BMW 335i
Fig. 213: Removing Valve Spring & Spring Retainer

IMPORTANT: Incorrect installation possible.
Incorrect installation will result in valve spring breakage.
Color marking (1) is normally on lower end of valve spring.
Installation:
Inlet valve: Violet/green or violet/yellow
Exhaust valve: White/green or white/yellow

2007 BMW 335i
If the colors on the valve springs can no longer be identified, these must be replaced for safety reasons.
Fig. 214: Identifying Color Mark On Valve Spring

Arrangement:
1. Valve
2. Valve stem seal with spring plate, bottom
3. Valve spring
4. Top plate spring
5. Valve tapers
Fig. 215: Identifying Valve Arrangement Position

Assemble engine.
36 VARIABLE CAMSHAFT TIMING

2007 BMW 335i
11 36 046 REMOVING AND INSTALLING/REPLACING INLET AND EXHAUST ADJUSTMENT

UNITS (N54)
 11 0 300
 11 4 280
 11 4 281
 11 4 283
IMPORTANT: To open central bolts on adjustment units and camshafts.
Fit special tool 11 4 280. See 11 4 280 GAUGE

Slide in special tool 11 0 300 in direction of arrow. See 11 0 300 PLUG MANDREL
Rotate flywheel (1) at central bolt until firing TDC position at 1st cylinder is reached.
IMPORTANT: The TDC bore can be mixed up in automatic transmissions.

2007 BMW 335i

With 1st cylinder in firing TDC position, inlet camshaft (1) at 6th cylinder points downwards at an angle to the
left.
With 1st cylinder in firing TDC position, exhaust camshaft (2) at 6th cylinder points downwards at an angle to
the right.
Installation:
If the timing is checked while the engine is installed, this can only be checked with a mirror.

Fit special tool 11 4 283 with screws (1).
Fit special tool 11 4 281 on special tool 11 4 283.

2007 BMW 335i

Release central bolt of exhaust adjustment unit (1).
Release central bolt of inlet adjustment unit (2).
Tightening torque, see 11 36 1AZ im ENGINE -- TORQUE SPECIFICATIONS -- TWIN TURBO
Release chain tensioner . See 11 31 090 INSTALLING AND REMOVING/REPLACING CHAIN

TENSIONER PISTON (N54)

Detach exhaust adjustment unit (1) from exhaust camshaft.
Detach inlet adjustment unit (2) from inlet camshaft.
Installation:
To facilitate removal and installation of adjustment units, turn sensor gears at cutout downwards.
2007 BMW 335i
Fig. 221: Identifying Inlet & Exhaust Adjustment Unit

IMPORTANT:  Danger of mixing up adjustment units.

 Mixing up the adjustment units will result in engine damage.
The inlet and exhaust adjustment units are different.
VANOS is marked with AUS and EX for the exhaust camshaft.
VANOS is marked with EIN and IN for the inlet camshaft.
Sensor gears can be fitted alternatively.
Fig. 222: Identifying Marked With AUS & EX For Exhaust Camshaft
Illustration number 1170-09
Fit both adjustment units on camshafts.

2007 BMW 335i
The installation position of the adjustment units can be freely selected.
Installation:
Replace screws (1 and 2).
Insert screws (1 and 2).
Fit chain tensioner.
Secure screws (1 and 2).

IMPORTANT: Incorrect installation possible.
Make sure that timing chain is guided in tensioning rail (1).
NOTE: Schematic representation on removed chain drive.

2007 BMW 335i
Fig. 224: Identifying Timing Chain

Assemble engine.
40 OIL SUPPLY
11 40 000 CHECKING ENGINE OIL PRESSURE (N54)
 11 4 050
 13 3 061
 13 3 063
 13 6 051
 13 6 054
Disconnect plug connection on oil pressure switch (1)
Remove oil pressure switch (2).
Tightening torque, see 12 61 1AZ in 61 OIL PRESSURE/OIL TEMPERATURE GAUGE

2007 BMW 335i
Fig. 225: Identifying Oil Pressure Switch

Screw in special tool 11 4 050 with sealing ring. See 11 4 050 REDUCER
Fig. 226: Identifying Special Tool (11 4 050) With Sealing Ring
Check engine oil pressure with diagnosis tester.
Connect special tools 13 6 054 and 13 6 051.
Check engine oil pressure with pressure gauge.
Connect special tools 13 3 063 and 13 3 061.
Start engine and check engine oil pressure.
Specified values.
2007 BMW 335i

Assemble engine.
41 OIL PUMP WITH FILTER AND DRIVE

11 41 000 REMOVING AND INSTALLING OIL PUMP (N54)
 11 0 300
 Removing oil pan.
Release screws (1).
Installation:
Remove intake pipe (2) in direction of arrow.

2007 BMW 335i
Fig. 228: Identifying Intake Pipe & Screws

Secure oil pump sprocket wheel with special tool 11 0 300 to oil pump. See 11 0 300 PLUG MANDREL
IMPORTANT: Release central bolt (2) with special tool 11 0 300 only. See 11 0 300 PLUG
MANDREL
Fig. 229: Identifying Special Tool (11 0 300) On Oil Pump


2007 BMW 335i
Fig. 230: Identifying Screws (2)

Release screws (1).
Installation:

Detach sprocket wheel (1) in direction of arrow.
NOTE: Timing chain (3) of triangular drive is pressed upwards by chain tensioner.
Do not remove sprocket wheel.
Remove oil pump (2) in direction of arrow.

2007 BMW 335i
Fig. 232: Identifying Sprocket Wheel, Oil Pump & Timing Chain
Installation:
Check spacer bushings (1) for secure seating and damage; replace if necessary.
Align twin surface (3) on oil pump (2) to sprocket wheel.
Install oil pump (2).
Fig. 233: Identifying Oil Pump, Sprocket Wheel With Spacer Bushings
Assemble engine.
11 41 010 REMOVING AND INSTALLING/REPLACING CHAIN MODULE FOR OIL

PUMP/VACUUM PUMP (N54)
 11 0 290
2007 BMW 335i
 11 0 300
 11 4 120
 11 4 280
 11 5 200
 11 8 640
 11 8 650
 11 9 190
 11 9 280
damage).

 Remove engine oil sump.
 Remove tensioner for drive belt.
 Remove vibration damper at front.
 Remove sealing cover for vacuum pump.
 Remove chain tensioner.
Turn sprocket wheel (3) at central bolt (crankshaft) into position.
Screw special tool 11 8 650 into crankcase. See 11 8 650 HOLDER
Position special tool 11 0 290 on sprocket wheel and on special tool 11 8 650. See 11 8 650 HOLDER
Release screw (1).

2007 BMW 335i
Fig. 234: Identifying Special Tool (11 0 290) On Sprocket Wheel

Press timing chain with chain tensioner (1) in direction of arrow.
Secure chain module with special tool 11 4 120 in bore (2). See 11 4 120 LOCKING PIN
Feed out sprocket wheel (3) at hexagon head of vacuum pump (4).
Installation:
A lock pin is pre-installed if the triangular drive is replaced.
Fig. 235: Identifying Special Tool (11 4 120) In Bore

Secure oil pump sprocket wheel with special tool 11 9 190 to oil pump housing.
Release bolt (2) on sprocket wheel.

2007 BMW 335i
Fig. 236: Identifying Special Tool (11 9 190) To Oil Pump Housing
Release screws (2).
Fig. 237: Identifying Screws (2)

Secure crankshaft and camshaft.
Do not remove special tools 11 0 300 and 11 4 280. See 11 0 300 PLUG MANDREL and 11 4 280 GAUGE
Fit special tool 11 9 280.
Release central bolt (1).
NOTE: A 3/4 inch tool is needed to release the central bolt.
A second person is required.

2007 BMW 335i
Fig. 238: Identifying Special Tool (11 9 280) On Central Bolt

Remove hub (2) towards front.
Installation:
Replace radial seal at front.
Fig. 239: Identifying Radial Seal Hub

Open screw plug on bedplate.
Installation:
Replace seal.
Release screw (1) with special tool 11 8 640 on triangular drive. See 11 8 640 TORX SOCKET E10

2007 BMW 335i
Installation:

Remove triangular drive (1) in direction of arrow.
Fig. 241: Identifying Triangular Drive

IMPORTANT: Note installation direction of sprocket wheel (2).
Collar on sprocket wheel (2) points to timing chain drive.
Incorrect assembly will result in engine damage.

2007 BMW 335i
Fig. 242: Locating Sprocket Wheel

IMPORTANT: The N54 engine requires special friction plates between the friction surfaces.
The engine will incur damage if the plates are damaged or are not fitted.
Friction plates (1 and 2) must be clipped into place on the oil pump module sprocket wheel.
The third friction plate is attached to the crankshaft hub.
Fig. 243: Identifying Friction Plates

Feed in oil pump chain module.
Secure oil pump chain module with screws (2).
Secure screw (1) with special tool 11 8 640. See 11 8 640 TORX SOCKET E10
2007 BMW 335i
Installation:
Check both friction plates (3) with retainers for correct installation position.
Fig. 244: Identifying Friction Plates Screw

Push on friction plate (1) without retainers.
IMPORTANT: The N54 engine requires special friction plates between the friction surfaces.
The engine will incur damage if the plates are damaged or are not fitted.
Fig. 245: Identifying Friction Plate

Fit central bolt (1).

2007 BMW 335i
Fig. 246: Identifying Central Bolt

Install special tools 11 8 650 and 11 0 290. See 11 8 650 HOLDER and 11 0 290 HOLDER
Tighten the screw (1).
Fig. 247: Identifying Special Tools (11 8 650 & 11 0 290) On Screw
Install special tool 11 0 300. See 11 0 300 PLUG MANDREL
Tighten the screw (2).

2007 BMW 335i
Fig. 248: Identifying Special Tool (11 9 190) To Oil Pump Housing
Tighten down special tool 11 5 200 with screws (1) to hub. See 11 5 200 SPACER RING
Do not remove special tools 11 0 300 and 11 4 280. See 11 0 300 PLUG MANDREL and 11 4 280 GAUGE
Fig. 249: Identifying Special Tool (11 5 200) With Screws To Hub
Tighten central bolt to jointing torque.
Apply stroke of paint (1) for torsion angle tightening to tool. See Fig. 250 .
IMPORTANT: Do not remove tool from central bolt during torsion angle tightening - risk of
damage .
2007 BMW 335i
Fig. 250: Applying Stroke Of Paint For Torsion Angle

Installation:
Replace radial seal at front.
Assemble engine.
51 WATER PUMP WITH DRIVE

11 51 000 REMOVING AND INSTALLING/REPLACING WATER PUMP (N54)
WARNING: Danger of scalding!
Only perform these tasks on an engine that has cooled down.
Recycling:
Catch and dispose of drained coolant.
damage).
If a water pump which has already been operated is reused, it must be filled
immediately after being removed with coolant (mixture ratio 1:1 / water:
coolant).
2007 BMW 335i
 Remove coolant thermostat.
Disconnect water hose (1).
Release screws (5).
Installation:
Installation:
If the water pump is to be reused, it must be mechanically rotated once (breakaway torque at impellers).
One water pump rotation will be sufficient.
Fig. 251: Identifying Plug Connection & Water Hose

Assemble engine.
Venting instructions must be observed without fail.
53 THERMOSTAT AND CONNECT

11 53 000 REMOVING AND INSTALLING/REPLACING COOLANT THERMOSTAT (N54)

2007 BMW 335i
Recycling:

 Drain coolant from radiator.
Release hose clamp (1) and detach coolant hose.
Release hose clamp (2) and detach coolant hose.
Unlock and detach coolant hose (3).
Release screws (6).
Remove coolant thermostat (7).
NOTE: Illustration shows coolant thermostat removed.
Fig. 252: Identifying Hose Clamp, Coolant Hose & Coolant Thermostat
2007 BMW 335i
Assemble engine.
11 53 740 REMOVING AND INSTALLING OR REPLACING WATER PIPE (N54)
Recycling:

 Drain coolant from radiator.
 Remove both primary catalytic converters.
Detach water pipe in direction of arrow from water pump (2).
Fig. 253: Detaching Water Pipe From Water Pump

Remove water pipe in direction of arrow.
Installation:
2007 BMW 335i
Seal (1) must not show any traces of damage; check and if necessary replace.
Fig. 254: Identifying Water Pipe & Screws

Release screws (1).
Disconnect water pipe (2).
Installation:
Replace all seals.
Fig. 255: Locating Water Pipe & Screws

Assemble engine.
Vent cooling system and check for leaks.

2007 BMW 335i
61 INTAKE MANIFOLD
11 61 368 REPLACING CHARGE-AIR DUCT (N54)
 Switch off ignition

 Remove intake filter housing. (See 13 71 000 REMOVING AND INSTALLING/REPLACING
IMPORTANT: Charge-air hoses with clamp fastenings must be installed dry and free from
grease!
If charge-air hoses with clamp fastenings are not installed dry and free from
grease, this may result in turbocharger failure!
Unfasten clip.
Tightening torque, see 13 71 6AZ in 13 71 AIR INTAKE SILENCER
Installation:
Install charge-air hoses dry and free from grease.
Detach charge-air hose (1) from charge-air duct (2).
Fig. 256: Detaching Charge-Air Hose From Charge-Air Duct

Release quick-connect couplings (1) by turning lock through 90°.
Detach recirculated air hoses (2) and lay to one side.

2007 BMW 335i
Fig. 257: Identifying Quick-Connect Couplings & Recirculated Air Hoses

Installation:
Pay attention to markings.
Recirculated air hoses must audibly snap into place.
Fig. 258: Identifying Lock Installation Position

Unlock plug (1) and remove.

2007 BMW 335i
Fig. 259: Unlocking Plug

IMPORTANT: Coat sealing rings of quick-connect couplings with antiseize agent.
Pressure pipes cannot be fitted without anti-seize agent!
Release screw.
Tightening torque, see 13 71 4AZ in 13 71 AIR INTAKE SILENCER
Unlock quick-connect coupling (1).
Detach charge-air duct (2) from throttle valve assembly and remove.
Installation:
Coat sealing ring of quick-connect coupling with antiseize agent.
Charge-air duct (2) must snap audibly into place.

2007 BMW 335i
Fig. 260: Identifying Charge-Air Duct & Quick-Connect Coupling

Assemble engine.
Read out fault memory of DME control unit
11 61 050 REMOVING AND INSTALLING INTAKE AIR MANIFOLD (N54)
 Remove tension strut.

 Remove suction filter housing. (See 13 71 000 REMOVING AND INSTALLING/REPLACING
 Remove engine cover.
Detach crankcase breather at cylinder head cover (1).
Fig. 261: Detaching Crankcase Breather Cylinder Head Cover

Pull off vacuum hose (1).
Detach tank vent valve (2) from mounting.
Release hose (3) and set down in engine compartment.

2007 BMW 335i
Fig. 262: Identifying Vacuum Hose, Tank Vent Valve & Hose
Disconnect plug connection (1) on oil pressure switch.
Fig. 263: Identifying Oil Pressure Switch

Release retainers (1) on fuel rail and place to one side.
NOTE: Do not detach fuel line.
Unscrew nuts (3).
Release screw (4).

2007 BMW 335i
Fig. 264: Identifying Fuel Rail Retainers

Raise intake air manifold.
Release screws (1).
Set down distributor housing (2) in engine compartment.
Fig. 265: Identifying Distributor Housing With Screws

Cut cable tie (1).
Installation:
Replace all seals (3).

2007 BMW 335i
Fig. 266: Identifying Plug Connection & Seals

Installation:
Replace all seals.
Assemble engine.
65 SUPERCHARGER WITH CONTROL

11 65 022 REMOVING AND INSTALLING/REPLACING EXHAUST-GAS TURBOCHARGER FOR
CYLINDERS 1-3 (N54)
IMPORTANT: It is not necessary to carry out a chassis/wheel alignment check to release the
steering tie rod.
 Remove both catalytic exhaust-gas converters.

 Remove intercooler.
 Drain coolant.
 Remove coolant expansion tank.
 Remove coolant thermostat. (See 11 53 000 REMOVING AND INSTALLING/REPLACING
COOLANT THERMOSTAT (N54))
 Remove coolant pump. (See 11 51 000 REMOVING AND INSTALLING/REPLACING WATER
PUMP (N54))
 Remove both vacuum reservoirs.
 Remove front pipe to turbocharger.
 Remove right charge-air duct. (See 11 61 368 REPLACING CHARGE-AIR DUCT (N54))
 Release tie rod from steering gear.
2007 BMW 335i
Release screws (1).
Installation:
Replace seal.
Release screw (2).
Tightening torque, see 11 42 8AZv in ENGINE -- TORQUE SPECIFICATIONS -- TWIN TURBO
Remove oil return pipe in direction of arrow.
Installation:
Replace O-ring.
Fig. 267: Locating Oil Return Pipe Screw

Undo screws (1 and 2)
Release coolant feed lines (3 and 4) if necessary with suitable pliers.
IMPORTANT: Do not position pliers on pipes - risk of damage! .

2007 BMW 335i
Fig. 268: Identifying Water Pipe & Screws

Release screws (1).
Remove feed line (2).
Installation:
Replace O-ring.
Fig. 269: Identifying Feed Line With Screws

Release screw (1).
Release coolant return pipe at connection (2) if necessary with suitable pliers.
2007 BMW 335i
Release screw (3).
Release coolant return pipe at connection (4) if necessary with suitable pliers.
Unfasten coolant return pipe.
Fig. 270: Identifying Coolant Return Pipe Connection

Release screws (1).
Release screws (3).
Tightening torque see 11 65 2AZ in ENGINE -- TORQUE SPECIFICATIONS -- TWIN TURBO

2007 BMW 335i
Fig. 271: Identifying Retaining Plate & Screws

Remove heat shield (1) in direction of arrow.
NOTE: Carefully swing heat shield out in direction of arrow - risk of damage!
Coolant feed pipe can be removed with heat shield.
Fig. 272: Removing Heat Shield

Release screws (1).
Place retaining plate (2) on cylinder head cover.

2007 BMW 335i
Fig. 273: Identifying Retaining Plate On Cylinder Head Cover

Release screw (1).
Detach oil feed line in direction of arrow.
Installation:
Replace O-ring.
Fig. 274: Detaching Oil Feed Line

Release screw (1).
Release oil pressure line (2) if necessary with suitable pliers.

2007 BMW 335i
Fig. 275: Identifying Oil Pressure Line With Screw

Unscrew nuts (1).
Remove turbocharger towards top.
IMPORTANT: Risk of damage! To wastegate linkage.
Do not misuse wastegate linkage for carrying.
Fig. 276: Identifying Turbocharger Nuts

Replace graphite rings (1).
NOTE: Illustration shows turbocharger (cyl. 4 to 6).

2007 BMW 335i
Fig. 277: Identifying Turbocharger Graphite Rings

Assemble engine.
Clear DME fault memory.
11 65 022 REMOVING AND INSTALLING/REPLACING EXHAUST-GAS TURBOCHARGER FOR

CYLINDERS 4-6 (N54)
 Remove both catalytic exhaust-gas converters.

 Remove intercooler.
 Drain coolant.
 Remove coolant expansion tank.
 Remove coolant thermostat. (See 11 53 000 REMOVING AND INSTALLING/REPLACING
COOLANT THERMOSTAT (N54))
 Remove coolant pump. (See 11 51 000 REMOVING AND INSTALLING/REPLACING WATER
PUMP (N54))
 Remove both vacuum reservoirs.
 Remove front pipe to turbocharger.
 Remove right charge-air duct.
Release screws (1).
Installation:
Replace seal.
2007 BMW 335i
Release screw (2).
Remove oil return pipe in direction of arrow.
Installation:
Replace O-ring.
Fig. 278: Removing Oil Return Pipe

Undo screws (1 and 2)
Release coolant feed lines (3 and 4) if necessary with suitable pliers.
IMPORTANT: Do not position pliers on pipes - risk of damage!.
Installation:
Replace O-rings.
2007 BMW 335i
Fig. 279: Identifying Water Pipe And Screws

Release screws (1).
Installation:
Replace O-ring.
Fig. 280: Identifying Feed Line With Screws

Release screw (1).
Release coolant return pipe if necessary with suitable pliers.

2007 BMW 335i
Installation:
Replace O-ring.

Release screw (1).
Release coolant return pipe (3) if necessary with suitable pliers.
Release coolant return pipe (2) if necessary with suitable pliers and remove.
Installation:
Replace O-ring.
2007 BMW 335i
Fig. 282: Identifying Coolant Return Pipe With Screw

Release screw (1).
Detach oil feed line in direction of arrow.
Installation:
Replace O-ring.
Fig. 283: Detaching Oil Feed Line

Release screws (1).

2007 BMW 335i
Release screws (1).
Fig. 285: Locating Screws

Remove heat shield (1) in direction of arrow.
NOTE: Carefully swing heat shield out in direction of arrow - risk of damage!
Coolant feed pipe can be removed with heat shield.
Fig. 286: Removing Heat Shield

Release screws (1).
Place retaining plate (2) on cylinder head cover.

2007 BMW 335i
Fig. 287: Identifying Retaining Plate On Cylinder Head Cover

Unscrew nuts (1).
Remove turbocharger towards bottom.
IMPORTANT: Risk of damage! To wastegate linkage.
Do not misuse wastegate linkage for carrying.
Fig. 288: Identifying Turbocharger Nuts

Replace graphite rings (1).

2007 BMW 335i
Fig. 289: Identifying Graphite Rings

Assemble engine.
66 VACUUM PUMP
11 66 000 REMOVING AND INSTALLING/REPLACING VACUUM PUMP (N54)
 11 0 290
 11 4 120
 11 8 650
 Remove drive belt. (See 11 28 010 REPLACING ALTERNATOR DRIVE BELT (N54))
 Remove tensioner for drive belt. (See 11 28 020 REPLACE ALTERNATOR DRIVE BELT
TENSIONER (N54))
 Remove sealing cover for vacuum pump. (See 11 14 010 REPLACING VACUUM PUMP SEALING
COVER (N54))
 Remove intake air manifold. (See 11 61 050 REMOVING AND INSTALLING INTAKE AIR
MANIFOLD (N54))
 Remove H.P. pump.
Rotate crankshaft at central bolt.
Turn sprocket wheel until drilled holes and screws of vacuum pump match up.
Screw in special tool 11 8 650. (See 11 8 650 HOLDER )

2007 BMW 335i
Secure special tool 11 0 290 in sprocket wheel and to special tool 11 8 650. (See 11 0 290 HOLDER and 11 8
650 HOLDER )
Release screw (1).
Fig. 290: Identifying Special Tool (11 0 290) In Sprocket Wheel

Press chain tensioner (1) with chain in direction of arrow.
Insert special tool 11 4 120. (See 11 4 120 LOCKING PIN )
Remove sprocket wheel (2) in direction of arrow.
Fig. 291: Inserting Special Tool (11 4 120)

Release screws (1).

2007 BMW 335i
Release screws (1), secure against falling out.
Remove vacuum pump.
Installation:
Replace seal.

Assemble engine.
78 EMISSION CONTROL OXYGEN

11 78 513 REMOVING AND INSTALLING/REPLACING BOTH LAMBDA OXYGEN CONTROL
SENSORS (N54)
 11 7 030
 11 9 150
WARNING: Scalding hazard!
Only perform these tasks after the exhaust system has cooled down.

 Release right tie rod on steering gear. (See 32 21 231 REPLACING LEFT OR RIGHT TIE ROD
and/or 32 21 231 REPLACING LEFT OR RIGHT TIE ROD )
2007 BMW 335i
Chassis/wheel alignment is not required.
Installation:
If an oxygen sensor is to be reused, only apply a thin and uniform coat of Never Seez Compound (refer to
BMW Parts Service) to thread.
The part of the oxygen control sensor which projects into the exhaust system branch (sensor ceramic) must not
be cleaned or come into contact with lubricant.
Disconnect plug connection for oxygen control sensor, cylinders 1 to 3.
Release oxygen control sensor (1) with special tools 11 7 030 and 11 9 150. (See 11 7 030 SOCKET
WRENCH SOCKET WAF 22 and 11 9 150 SPECIAL WRENCH )
Installation:
Cable color black, cylinders 1 to 3.
Fig. 293: Identifying Special Tools (11 7 030 & 11 9 150) On Oxygen Control Sensor Cylinders 1 To 3
Disconnect plug connection for oxygen control sensor, cylinders 4 to 6.
Release oxygen control sensor (1) with special tools 11 7 030 and 11 9 150. (See 11 7 030 SOCKET
WRENCH SOCKET WAF 22 and 11 9 150 SPECIAL WRENCH )
Installation:
Cable color gray, cylinders 4 to 6.

2007 BMW 335i
Fig. 294: Identifying Special Tools (11 7 030 & 11 9 150) On Oxygen Control Sensor Cylinders 4 To 6
Assemble engine.
11 78 545 REMOVING AND INSTALLING/REPLACING BOTH LAMBDA OXYGEN MONITOR

SENSORS (N54)
 11 7 020
 11 7 030
 11 9 150
Only perform these tasks after the exhaust system has cooled down.
Installation:
If an oxygen sensor is to be reused, only apply a thin and uniform coat of Never Seez Compound (refer to
BMW Parts Service) to thread.
The part of the oxygen monitor sensor which projects into the exhaust system branch (sensor ceramic) must not
be cleaned or come into contact with lubricant.
Disconnect plug connection for oxygen monitor sensor.

2007 BMW 335i
Release monitor sensor (1) with special tools 11 7 030 and 11 9 150. (See 11 7 030 SOCKET WRENCH
SOCKET WAF 22 and 11 9 150 SPECIAL WRENCH )
Installation:
Cable color black, cylinders 1 to 3.
Fig. 295: Identifying Special Tools (11 7 030 & 11 9 150) On Monitor Sensor
NOTE: Release insulation (2) in direction of arrow.
Disconnect plug connection for oxygen monitor sensor.
Release monitor sensor (1) with special tool 11 7 020. (See 11 7 020 SOCKET WRENCH SOCKET WAF
22 )
Installation:
Cable color gray, cylinders 4 to 6.

2007 BMW 335i
Fig. 296: Identifying Special Tools (11 7 020) On Monitor Sensor

Assemble engine.

2007 BMW 335i
ACCESSORIES AND EQUIPMENT Body - Repair Instructions
Body - Repair Instructions
BODY, GENERAL
AFGS (ACTIVE PEDESTRIAN PROTECTION) PROCEDURE AFTER ACCIDENT
The AFGS system consists of the following components:
 Satellites (control unit + sensor)

 Sensors, bumper panel inside
 ACSM control unit (Crash Safety Module)
 Cables and connectors

 Engine compartment lid hinges
 Actuator
 Engine compartment lid hinge
 Gas pressure spring
 Engine compartment lid catch (only E89)

 Catch, engine compartment lid
 Catch, upper section (striker)
In case of a frontal or side collision in the area of the engine compartment lid and/or the A-pillars, check
the following components:
Satellites (control unit + sensor)
 Procedure
 Read fault memory
 Disconnect battery and observe waiting period
 Rectify faults
 Reconnect battery and observe waiting period
 Delete fault memory
 Turn off ignition and wait at least 2 minutes (no consumers may be switched on during this period
such as e.g. interior lights, radio, etc.)
 Switch on the ignition
 Clear fault memory and if necessary rectify faults
Cables and connectors
 Procedure
2007 BMW 335i
 Check cables and connectors for damage, replace if necessary.
Gas pressure spring
 Procedure
 Check gas pressure spring for damage and replace if necessary.
Procedure if AFGS was activated:
Engine compartment lid hinges
 Replace actuators
 Check BOTH HINGES OF THE ENGINE COMPARTMENT LID and replace if necessary
 If hinges are OK, repair hinges with repair kit
Engine compartment lid catch (only E89)
 Replace both engine compartment lid catches

 Check the top sections of the catch and replace if necessary
Procedure if AFGS was not activated:
Engine compartment lid hinges
 Check BOTH HINGES OF THE ENGINE COMPARTMENT LID and replace if necessary
Engine compartment lid catch (only E89)
 Check both engine compartment lid catches and replace if necessary.

 Check the top section of the catch and replace if necessary.
41 00... BLIND RIVETS
1.0 Recommended tools and equipment
 Blind riveting tongs

 Rivet head extension
Setting blind rivets
 Position bore holes for blind rivets as specified in repair instruction. If necessary, carry over the positions
of the rivets to the new component.
 Drill holes (0.2 mm bigger than the outside diameter of the rivet. Example 4.2 mm dia. for 4 mm rivet and
6.7 mm dia. for 6.5 mm rivet).
 Deburr holes.
2007 BMW 335i
 APPLY ADHESIVE.
 Insert blind rivet. If necessary, remove adhesive that has emerged.
Position blind rivet tool vertically. Use rivet head extension if accessibility is poor.
 Rivet blind rivet with blind rivet tool. In the meantime clean rivet head if fouled with adhesive. Risk of
damage to rivet head by penetrating adhesive.
 Seal blind rivets with SEALANT (risk of corrosion).
 Seal cavities after painting vehicle with CAVITY SEALANT (risk of corrosion).
41 00... BONDING ON PAINTED SURFACES
IMPORTANT: Conform with safety regulations See SAFETY AT WORK and INFORMATION ON
HAZARDS!
Overview of topics
1. Equipment
2. Expiry date of consumables
3. Preparation of surface
4. Bonding coat
5. Hardening times
6. Subsequent treatment
7. Disposing of adhesive
1.0 Equipment
 Cleaner (refer to BMW Electronic Parts Catalogue)

 Adhesive as specified in repair instructions
 Cartridge Gun (refer to BMW Electronic Parts Catalogue)
2.0 Expiry date of consumables
 Glue cartridge is marked with a date.

 Do not use adhesive after this date.
3.0 Preparation of surface
3.1 Preparation of surface on vehicle
 Establish a level bonding surface (e.g. grinding). Do not remove primer entirely.
 Do not grind/sand bonding surfaces.
 If necessary, pre-clean bonding surfaces with cavity sealing wax remover.
2007 BMW 335i
Clean bonding surfaces with cleaning agent R1.
 Allow cleaned surfaces to dry for approx. 5 minutes.
Bonding surfaces must be completely dry.
3.2 Preparation of surface on new part
 Do not remove primer.

 Do not grind/sand bonding surfaces.
 Clean bonding surfaces with cleaning agent R1.
4.0 Adhesive application
 Processing temperature of glue cartridge 18°C-30°C.

 Object temperature, vehicle and new parts, min. 15°C.
 Do not use any compressed-air-operated cartridge guns.
 Insert glue cartridge in cartridge gun, remove cap and allow both adhesive components to emerge. Strip
adhesive components uniformly and attach mixing tube.
 Allow approx. 10 cm of mixed adhesive to emerge and then apply the mixed adhesive first on one side of
the bonding surface.
 After applying the adhesive, check whether an adhesive component has emerged at the back of the
cartridge. If yes, break off the bonding procedure. Clean new part. Use new glue cartridge. Contact
national hotline.
 Potlife of mixed adhesive approx. 2 hours. A change of mixer is only necessary if over a period of 30
minutes no material has flowed through the mixer.
 Join components and secure in position.
 Remove excess adhesive.
5.0 Hardening times
 Do not move the vehicle before the adhesive has hardened.
Check the degree of hardness of the adhesive with a fingernail.
If the adhesive cannot be pressed in any further with a fingernail, the vehicle may be moved (without
engine force) for further processing applications (e.g. painting).
 Vehicle strength for driving applications is achieved after:
48 hours at min. 15°C object temperature (corresponding to approx. 18°C room temperature).
2007 BMW 335i
or 1 hour in the spray booth (spray booth temperature 80°C/object temperature 60°C).
 When using radiant heaters, make sure that the object temperature does not exceed 85°C. Excessively
high temperatures will destroy the adhesive.
 Remove contamination caused by adhesive residue immediately.
Hardened adhesive can only be removed mechanically.
6.0 Subsequent treatment
 Reseal areas which are cavity-sealed as standard.
7.0 Disposing of adhesive
 Hardened adhesive is disposed of as normal waste.

 Empty glue cartridges are disposed of as normal waste.
 Non-hardened adhesives and mixtures of adhesive and solvent and the like must be disposed of as
hazardous waste.
These regulations apply to the Federal Republic of Germany.
For other countries, comply with the (possibly differing) nationally applicable regulations.
41 00... BONDING PLASTIC PARTS
IMPORTANT: Conform with safety precautions!
Plastic repair box:
Detailed in formation can be found in the:
 Current painting handbook
41 00... BONDING STEEL ON STEEL
Overview of topics:
1. Equipment
2. Expiry date of adhesive
3. Grinding and cleaning
4. Gluing coat
5. Hardening times
6. After treatment of bonding surfaces
2007 BMW 335i
7. Disposing of adhesive
1.0 Equipment
 Sandpaper
 Cleaning agent R1
 Adhesive K1
 Cartridge gun
2.0 Surface preparation
 For better adhesion, remove oxide film and paint from the adhesive areas with a stainless steel wire brush
or special sandpaper.
 Clean bonding surfaces with cleaning agent R1.
3.0 Adhesive application:
 Processing temperature of glue cartridge 18°C - 30°C.

 Object temperature, vehicle and new parts, min. 15°C.
 After applying the adhesive, check whether an adhesive component has emerged at the back of the glue
cartridge. If yes, break off the bonding procedure. Clean new part. Use new glue cartridge. Contact
national hotline.
 Join components and secure in position.
 Remove excess adhesive. Do not use solvent cleaning agents.
4.0 Hardening times:
 Refer to NOTES REGARDING ADHESIVE K1
5.0 Subsequent treatment of bonding surfaces
 Protect the repair area with cavity sealant.
41 00... CORROSION PROTECTION
NOTE: Following repairs, the corrosion protection work already begins with the correct
removal of the PVC undercoating, antinoise compound and seam seals.
1.0 Removing sealing materials:
IMPORTANT:  Do not burn off PVC material with a gas burner or similar or heat to
2007 BMW 335i
temperatures above 180°C. This would generate highly corrosive

hydrochloric acid and release harmful fumes.
 The new lining does not form a satisfactory bond with burnt PVC material
which means that subsequent sub-surface rust may set in.
Remove PVC material with a rotating steel brush, or heat PVC to maximum 180°C with a hot air blower and
scrape off with a spatula.
2.0 Corrosion protection of sheet-metal parts:
All weld joints sealed off with body sealing compound in original state must be primed and sealed off again
thoroughly after repairing. Replace damaged or removed antinoise compounds.
NOTE: Spray gun required for body sealing compound (order no. 81 49 0 300 887).
Concluding cavity protection is the most important part of all corrosion protection measures.
Use the cavity protection spray only for smaller-scale straightening work where the parts in question are easily
accessible. Use the HRS spray gun with pressure container for all other repairs. Cavity protection agent is
available in different container sizes.
Use the relevant probes with tubes for the different cavity areas.
IMPORTANT: Incorrectly performed cavity protection can, especially in the case of

steel/aluminium joints, give rise to a non-calculable product liability and safety
risk.
The best repair is worth nothing if the subsequent cavity protection measures are not conscientiously carried
out.
2.1 Cavity protection of steel parts:
New doors and lids must be sealed with cavity protection agent after being painted.
New sheet-metal parts or cavities, weld seams and folds formed by new sheet-metal parts must be sealed with
cavity protection agent after being painted.
The cavities affected must be sealed with cavity protection agent after all straightening work.
2.2 Cavity protection of aluminium parts:
New doors, lids and side panels made of aluminium are not sealed with cavity protection agent.
After all straightening work on aluminium components, the cavities affected must be sealed with cavity
protection agent after being painted.
2007 BMW 335i
After all welding work (E52 only) on aluminium components, the cavities affected must be sealed with cavity
protection agent after being painted.
Cavities, seams and folds formed from new sheet-metal parts must be sealed with cavity protection agent after
being painted.
41 00... EMC SCREWS
(EMC = Electro Magnetic Compatibility)
1. Purpose
 EMC screws are used in the Bonding/Riveting repair method to reestablish bonding transition.
 They assume the function of welded joints, which ensure transition to ground between the individual
components.
 The punch or blind rivets used in the repair do not guarantee permanent bonding transition between the
individual components!
 The EMC screws ensure the operational reliability and safety of the electrical/electronic components
following repairs!
2. Procedure, aluminum front end
 Each welded joint which is opened must be replaced by at least 2 EMC screws.
 Position the 2 screws on the flange on which the weld seam has been separated. In the event of partial
replacement, position the screws in the area of the component overlap.
 In the case of repairs using partial replacement, the number of EMC screws described in the repair
instructions must be fitted.
 Drill holes to a diameter of 4.2 mm and insert screws.
 Seal EMC screws with PU sealing material (risk of corrosion).
3. Procedure, steel body
 Install the number of EMC screws described in the repair instructions.

 Drill holes to a diameter of 4.2 mm and insert screws.
 Seal EMC screws with PU sealing material (risk of corrosion).
41 00... FRAME ALIGNMENT CONTROL DIMENSIONS, BODY
Dimensions in mm.
Measurement tolerances:
 < or = 1000 mm ± 1.5 mm

 > or = 1000 mm ± 2.5 mm
2007 BMW 335i
The control points shown serve to check the body and the straightening attachment.
The specified dimensions/measurements always refer to the centerpoint of the bore/screw.
Underbody view 1
Fig. 1: Frame Alignment Control Dimensions Body - Underbody View 1

Underbody view 2
Fig. 2: Frame Alignment Control Dimensions Body - Underbody View 2

Top view, front end

2007 BMW 335i
Fig. 3: Frame Alignment Control Dimensions Body - Top View, Front End
The specified dimensions refer to removed assemblies.
View, B-pillar (Saloon and Touring only)
Fig. 4: Frame Alignment Control Dimensions Body - View, B-Pillar (Saloon And Touring Only)
Measurement a=1551 mm between screw-on points of door brakes.
View, B-pillar (Coupe only)

2007 BMW 335i
Fig. 5: Frame Alignment Control Dimensions Body - View, B-Pillar (Coupe Only)
Measurement a=1543 mm between screw-on points of lock strikers.
41 00... GAP DIMENSIONS, BODY
NOTE: Symmetry of the gaps between left and right sides of the vehicle has top
priority.
The door gaps must not deviate between the front and rear gap by more than
1.0 mm.
Dimensions in mm
Fig. 6: Gap Dimensions Body - Front Panels Dimension In mm (1 Of 4)

Dimension (1) 0.8 ±0.8 is reduced in the rearward direction of travel to 0 ±0.8
Dimension (2) 1.5 ±1.0 is reduced in the downward direction to 0 ±1.5

2007 BMW 335i
Dimension (3) 0 ±0.7 is reduced in the forward direction of travel to 2.5 ±0.7
Fig. 7: Gap Dimensions Body - Sunroof/Roof Dimension In mm (2 Of 4)

Fig. 8: Gap Dimensions Body - Side/Door Panels Dimension In mm (3 Of 4)

Dimension (1) 4.5 ± 1.3 is reduced in the rearward direction of travel to 3.8 ± 1.1
2007 BMW 335i
Fig. 9: Gap Dimensions Body - Rear/Trunk Dimension In mm (4 Of 4)

Dimension (1) 1.0 ± 1.1 is reduced in the forward and rearward direction of travel to 0 ± 1.1
Dimension (2) 4.2 ± 0.7 is reduced on both sides with the start of the radius to 3.8 ± 0.7
41 00... GENERAL CEMENTING INSTRUCTIONS
 The bonding surfaces must be kept free of all types of dirt and contamination. Avoid leaving fingerprints.
 Cleanliness is the golden rule for all bonds!
 Cleaning agent: Isopropyl, acetone or spirit
Expiry date of adhesive and primer
 The adhesive cartridge and the primer are marked with a date.
 Do not use the adhesive or primer after this date.
2-component adhesive application:
 Insert adhesive cartridge in adhesive gun, remove cap and allow some adhesive to emerge. Strip adhesive
components uniformly and attach mixing tube.
 Allow approx. 1 mixer length of mixed adhesive to emerge (there must be no smearing of colors). Only
then apply the mixed adhesive to one side of the bonding surface.
Adhesive disposal:
 Hardened adhesive is disposed of as normal waste.

 Empty adhesive cartridges are disposed of as normal waste.
2007 BMW 335i
 Non-hardened adhesives and mixtures of adhesive and solvent and the like must be disposed of as
hazardous waste.
41 00... GRINDING STEEL PARTS
 Tools are recommended for manual grinding work.

 Machines/equipment are recommended for machine grinding work.
2.0 Grinding outer shell and structure
Always replace abrasives which have already been used to treat aluminum (risk of corrosion).
Do not grind the material thin.
41 00... GRINDING ALUMINUM PARTS
Grinding on the outer shell:
 To carry out grinding work by hand or machine, you must use the recommended tools and equipment.
The work area can be cleaned with conventional extractor systems (low dust concentration).
Grinding work on the structure (except Z8):
 To carry out grinding work by hand or machine, you must use the recommended tools and equipment.
The work area can be cleaned with conventional extractor systems (low dust concentration).
Z 8 Spaceframe structure:
 To carry out machine grinding on the structure, you must use the recommended device with grinding dust
extractor facility.
The work area must be cleaned with the recommended explosion-proof extractor system.
High dust concentration, explosion hazard!
2.0 Grinding outer shell and structure

2007 BMW 335i
Do not use any abrasives (grinding wheels, paper, etc.) which contain iron (risk of corrosion).
Always replace abrasives which have already been used to treat steel (risk of corrosion).
Use stainless steel wire brushes only (risk of corrosion).
Reduce speed of grinding machines. Excessive speeds cause a smearing effect.
Do not use coarse abrasive grains (only =. 80).
Do not grind notches into the material (risk of cracking).
Do not grind the material thin.
41 00... GUN FOR CAVITY SEALING
Fig. 10: Identifying Gun For Cavity Sealing

1.0 Scope of delivery
 Owner's Handbook
 Pressure vessel gun (1) for cavity sealing
 Spray set, consisting of spray hoses: angle nozzle (2) and round spray nozzle (3)
IMPORTANT: Before start-up, read Owner's Handbook and safety instructions.
2.0 Start-up
 Open pressure vessel and introduce cavity sealant in form of a 1- liter can.
Close pressure vessel.

2007 BMW 335i
 Connect spray hose to quick-connect coupling.

 Connect apparatus to compressed air supply.
Working pressure 2-6 bar, max. 8 bar!
3.0 Mode of operation
NOTE: Unlike previous apparatus, it is possible here to alter the spray pattern with the
air flow control screw (large knurled screw)!
 Twisting the air flow control screw in decreases the air flow and thus reduces the material spray mist.
This facilitates optimum working when preserving open components/surfaces.
 Twisting the air flow control screw out increases the air flow and thus the material spray mist (for closed
cavities).
 The trigger lever has two stages.
Stage 1 - discharge of air only.
Stage 2 - discharge of air and material.
 After finishing work, press the first stage to clean the spray hose with compressed air.
 When storing, remember to twist the air flow control screw closed to prevent the material from drying
out.
 Clean the gun prior to extended periods of non-use (approx. 2 weeks and upwards).
 To ensure that the spray hoses function properly, do not store the hoses coiled up e.g. in the frame side
member area!
Store spray hoses stretched out.
4.0 Application examples
 Use the matching spray hoses for the different cavities or surfaces.
 Example - doors and lids:
Spray hose with angle nozzle. Reduce air flow to keep spray mist to a minimum.
 Example - frame side member:
Long spray hose with round spray nozzle. Depending on the type, increase the air flow slightly.
 Always keep the spray mist to a minimum so as to avoid fouling and bad smells.
5.0 Safety instructions

2007 BMW 335i
 Do not inhale spray mist.

 Use only in well ventilated rooms.
 Working pressure max. 8 bar.
41 00... HANDLING AIRBAGS AND RESTRAINT SYSTEMS
1.0 Airbags and restraint systems
 On vehicles with airbags and restraint systems, observe the relevant Safety Instructions.
 During straightening work on the body, you will be exposed to the risk of accidental airbag triggering
when the battery is connected.
Due to this potential hazard, it is essential to Disconnect the battery negative lead prior to welding and
straightening work. Prior to disconnecting the negative lead, interrogate the fault memories of the control
units if necessary.
41 00... HANDLING ELECTRICAL AND ELECTRONIC EQUIPMENT
1.0 Battery
 There is a risk of explosion when welding or grinding work is carried out in the vicinity of the battery.
The battery must be Removed. Prior to removing the battery, interrogate the fault memories of the
control units if necessary.
2.0 Control units
 The following hazards are present when the battery is connected:

 Damage to control units du ring welding work on the body.
 Accidental triggering of airbags during straightening work on the body.
Due to these potential hazards, it is essential to Disconnect the battery negative lead prior to welding and
straightening work. Prior to disconnecting the negative lead, interrogate the fault memories of the control units
if necessary.
 Control units are designed for a temperature of 65°C. The temperatures in a spraying booth do not pose
any problems. If a vehicle is inside the spraying booth at an indicated temperature of 80°C, the actual
temperature of the vehicle will be < or = 60°C (object temperature).
 Protects control units against the effects of heat at temperatures > 65°C (e.g. during welding and drying
with an infrared radiator or hot air blower).
3.0 Electric cables and wiring harnesses
 Protect electric cables and wiring harnesses against damage (e.g. during straightening and grinding work).
 Protect electric cables and wiring harnesses against the effects of heat at temperatures > 65°C (e.g. during
welding and drying with an infrared radiator or hot air blower).
2007 BMW 335i
 Do not kink electric cables.
4.0 Optical fibers
 Follow instructions for handling Optical Fibers.
41 00... INFORMATION / WARNING LABELS
Missing or damaged information/warning labels (e.g. tire inflation pressure) must be replaced.
--> Overview of Installation Locations
41 00... INFORMATION ON HAZARDS
1.0 Aluminum
ALUMINUM
Hazards / effects Measures / regulations
Repair stage 1:  When a vehicle outer shell is ground,
(replacement of bolted parts, dent removal) aluminum dust accumulates in small amounts.
Repair stage 2: This dust can be removed with conventional
(structural repairs with bonding and riveting) extractor systems.
Repair stage 3:  Avoid high concentration of fine aluminum
(structural repairs with welding) dust by means of continuous extraction.
 Use explosion-proof extractor systems.
 Explosion hazard due to high concentration of
fine aluminum dust.  Do not use compressed air when cleaning the
work bay.
Arising e.g. during straight-through grinding  Avoid swirling up dust when cleaning the
of coated parts in the base material and large- work area.
surface grinding of bright-finish parts.
 Explosion hazard due to swirling up of fine

aluminum dust in cavities.
Created by the necessary, thorough cleaning

of machining surfaces and tools before and
after machining aluminum.
 Spontaneous combustion of fine aluminum  Do not operate ignition and fire sources in the
dust when ignition and fire sources are drawn in take area of extractor systems.
in.
E.g.: hot splinters, grinding sparks, cigarettes

etc.
41 00... INFORMATION ON METAL FILLER

2007 BMW 335i
IMPORTANT: Note the following information before starting to apply metal filler!
 Country-specific safety and industrial safety regulations

 Material safety data sheet of manufacturer
 Processing instructions on the packaging
Storage
Dry at 15°C to 25°C.
Shelf life
The packaging is marked with a date.
Do not use the metal filler after this date.
Surface pre-treatment
Grind surface to a metallic bright-finish. The surface must be clean, dry and free from grease.
Clean the surface with a cleaning agent R1 and let it vent for 2-3 minutes.
Processing
The working temperature of the metal filler must be at least 18°C.
Fig. 11: Identifying Metal Filler And Hardener

A = Metal filler
B = Hardener
2007 BMW 335i
NOTE: The mixture ratio refers to the volume.
Mix metal filler in mixture ratio of 5:2. Mix components thoroughly and free of pores.
IMPORTANT: Do not stir components. Danger of air pockets in metal filler!
Working life of the metal filler is approx. 45 minutes.
Applying filler
Apply pressure to apply a thin layer of metal filler. Carefully coat all edges in gaps with filler.
Then fill gap completely with filler. Apply filler with about 30% excess because the filler will significantly
shrink during hardening. A second application of metal filler is not possible due to poor adhesion.
IMPORTANT: Use a narrow spatula to fill the gaps. Apply the filler in one draw if possible.
Danger of formation of pores in gaps!
No restrictions related to the layer thickness.
Hardening time
The metal filler must be hardened using a short-wave infrared heater.
 10 minutes at 50°C - pre-hardening (avoid formation of bubbles/blisters and pores)

 10 minutes at 75°C - 1st stage hardening
 10 minutes at 85°C - 2nd stage hardening (avoid material shrinkage)
IMPORTANT: In the first 10 minutes, the temperature of 50°C may not be exceeded. In
contrast, a temperature that is too low may be equalized by extending the time.
NOTE: When the heater is used for the first time, the distances that match the
temperature must be determined.
Switch the heater on and change the distance until the surface temperature of the metal filler no longer changes
for a period of 2 minutes. Measure the temperature with a temperature gauge. When optical temperature gauges
are used (Epsilon value 0.92-0.95), the heater must be switched off briefly during the measurement. Record the
measurement
Post-processing
WARNING: When grinding, wear a fine dust mask with particulate filter P2-P3!
After cooling, the metal filler can be machined.

2007 BMW 335i
Pores and faulty spots that become visible after grinding the surface must be closed with polyester filler (BMW
Color system).
Special procedure for pores:
Use a Ø4.2mm drill. Turn the drill by hand to expand the pores in v shape. by t
Fill cavities with polyester filler.
Paintwork
Perform paintwork according to the specifications in the painting handbook.
Metal filler disposal
Hardened metal filler is disposed of as normal waste.
Empty packaging is disposed of as normal waste.
Non-hardened metal filler and mixtures of metal filler with solvent and the like must be disposed of as
hazardous waste.
32 00... INFORMATION ON REPLACING STEERING GEAR AFTER ACCIDENT DAMAGE
Situation
In the event of accidents or driving conditions similar to accidents, shock-like loads can cause different types of
damage to steering gears. When a steering gear is externally undamaged, it is sometimes only possible to
identify damage with great difficulty and with great effort. However, damage of this nature poses an
unacceptable risk to the vehicle because it can result in failure of the steering system.
Because of the disproportionate amount of effort involved, it is generally not sensible to check thoroughly all
the individual components of the steering gear and as an alternative it is necessary to take into account other
components which can be checked more easily.
Procedure
The steering gear must be replaced if one or more of the following points apply:
A. Visible or noticeable damage to the steering gear

 Version with electric steering gear (EPS): Examine in particular the control unit with all plug
connections for damage and hairline cracks.
B. Unacceptable torque increase and jamming when the steering gear is turned from lock to lock (without
2007 BMW 335i
hydraulic/electrical assistance)
C. Permissible tolerances exceeded during axle/wheel alignment (include alignment record with
invoice/report if necessary)
D. Fire damage
E. Damage, permanent deformation or fractures to:
 Wheel rims in the event of a negative result from the wheel/axle alignment check
 Spring struts, steering knuckles, wheel carriers
 Control arms
 struts or diagonal members or stabilizers with this function
 Body-side screwing/bolting points for wheel guide/control components
 Front axle support
 Pitman arms
 Tie rods
 Steering gear fixtures
 Steering Column
64 00 000 INFORMATION ON USING CLEANING AGENT/PAINTS (PERSONAL PROTECTION

EQUIPMENT)
WARNING: Use of cleaning agents/paints not compliant with instructions can cause
serious injuries or burns!
Handling cleaning agents/paints can trigger allergic skin and respiratory
reactions!
IMPORTANT: Observe following instructions:
 Store cleaning agents/paints only in a secure cabinet.

 Keep cleaning agents/paints away from naked flames and other sources
of ignition.
 Protect cleaning agents/paints from high temperatures and direct
sunlight.
 Always keep an eye bath on hand, change the water regularly (once a
month).
IMPORTANT: Observe following instructions before use:
 Manufacturer's instructions (on container/packaging)

 Hazard warnings (on container/packaging)
 Manufacturer's instructions on package insert
 Material safety data sheet of manufacturer
 Product information in EPC
2007 BMW 335i
 National market regulations
IMPORTANT: Observe following instructions during use:
 Do not eat, drink or smoke while working with these products.

 Avoid direct contact with skin and eyes.
 Wear personal protective clothing/equipment.
 Ensure that all enclosed areas are well ventilated or extract fumes
directly.
 Immediately change working clothes soiled with cleaning agent/paint.
 After finishing work, wash your hands and apply protective skin cream.
IMPORTANT: Follow hazard warnings and wear personal protection equipment!
First Aid:
 If product comes in contact with eyes, immediately flush with running water for about 10-15 minutes.
Seek the advice of eye specialist.
 In the event of skin contact and where applicable an allergic skin reaction, clean the affected areas
immediately with soap and water and then apply silicone-free skin cream. Seek advice of physician.
 If an adhesive product is swallowed, rinse mouth/parts of mouth thoroughly with running water. Drink 1-
2 glasses of water. Do not induce vomiting. Consult a doctor.
 After inhaling vapors ensure ample supply of fresh air. Keep calm, keep respiratory tracks clear and call
doctor.
Recycling
Dispose of cleaning agents/paints in a professional manner!
Observe national/country-specific disposal regulations.
41 00... INFORMATION ON VEHICLE PROTECTION
 Vehicle components which are situated in the repair area or exposed to heat, flying sparks or dust must be
removed or covered.
IMPORTANT: Do not use combustible or contaminated coverings.
41 00... INSTALLATION OF A CAVITY SEAL WITH CAVITY FOAM
IMPORTANT: The cavity foam may only be use for cavity sealing at the points at which cavity
sealing is present as standard!
2007 BMW 335i
The following repair represents the replacement of a shaped part for the cavity seal by the use of cavity foam.
This type of cavity sealing is used at points at which shaped parts cannot be used for repairs.
This is the case when large amounts of heat occur (e.g. due to welding, soldering or tin-plating) in the direct
vicinity or at the point of the standard cavity sealing.
It is not possible here to in stall shaped parts for the cavity seal because of the fire risk!
To replace shaped parts with cavity foam at further locations, adopt the procedure shown here and adapt it to the
relevant conditions.
It must be ensured that the cavity is completely sealed off.
NOTE: Check the accessibility for the spraying pipe of the cavity foam to the affected
cavity after removing the damaged part.
Properties of cavity foam:
 2K-PUR foam, solvent-free.

 Excellent flow capacity, enabling complete sealing of cavities.
 Good strength, preventing slipping in cavities.
 Low water absorption, preventing corrosion.
IMPORTANT: Observe processing instructions and safety precautions on the spray can!
 Use by date on can.
Do not use the spray can after the use-by date has expired as the
properties of the cavity foam would no longer meet the requirements of
the BMW Group.
 Before applying to the vehicle, fill a clearly visible cavity of corresponding

size with foam on a used part.
This enables an optimal dosage (i.e. spraying time) to be specified for

filling the cavity on the vehicle with foam.
 Backing surface must be clean and free from dust, grease, oil and
stripping agent.
 Tape off open passages to visible areas with adhesive tape to prevent
foam from escaping.
 Application time after mixing: within 8 minutes.
 Do not eat, drink or smoke during this operation.
 Completely empty open can after use.
2007 BMW 335i
 Cavity sealing of repair area possible after an air drying time of 1 hour.
41 00... INSTALLING A CAVITY BULKHEAD (EXPANDED)
NOTE: Carry over schematic representation to the relevant vehicle type.
The following repair represents the procedure for an already expanded cavity bulkhead.
The cavity bulkhead remains on the body in this instance.
Before these work steps, prepare the new part so that it is ready to install (adapting, cutting to size, applying
welding primer etc.).
Clean contact surface (1) with spirit.
Apply an approx. 15 mm high bead (2) of original BMW window adhesive to contact surface (1).
Fit, secure and weld up new part.
Fig. 12: Cavity Bulkhead Contact Surface And Bead Application Area
WARNING: Ensure adequate ventilation over entire processing period.
41 00... INSTALLING A CAVITY BULKHEAD (NOT EXPANDED)
The following repair represents replacement of a cavity bulkhead.
Before these work steps, prepare the new part so that it is ready to install (adapting, cutting to size, applying
welding primer etc.).
2007 BMW 335i
Sand contact surface of cavity bulkhead (1) with coarse-grained abrasive paper (grain 50 - 100).
Clean contact surface (1) with spirit.
Apply an approx. 15 mm high bead of original BMW window adhesive to contact surface (1).
Attach cavity bulkhead in specified position (see old part).
Fit, secure and weld up new part.
Fig. 13: Cavity Bulkhead Contact Surface And Bead Application Area
WARNING: Ensure adequate ventilation over entire processing period.
41 00... MATERIALS SCIENCE
1. Aluminum
1. Chassis and suspension components
Read and observe the Notes On Chassis And Suspension Components before handling
aluminum.
2. Material influences
MATERIAL INFLUENCES CHART

Causes Effects / remedies
A galvanic element is created under the effects of This plating process causes aluminium to be
moisture by contact with materials such as copper, removed from the joint.
tin, nickel, iron and zinc. This results in surface corrosion or pitting.
New parts and accessory parts which have been
approved by the BMW Group for aluminum (screws,
washers, nuts etc.) have undergone special surface
2007 BMW 335i
treatment.
Such parts must not be replaced by conventional
parts.
NOTE:
Damaged parts lose this protection and must be
specially coated or replaced.
Damage caused by contact corrosion is excluded
from the warranty.
Materials also used for work on steel components Surface corrosion or pitting occurs. A separate tool
can implant steel particles in the softer surface of an kit is available for processing/machining aluminum.
aluminium component.
Surfaces are attacked when fluxing agents are used. Soldering is not permitted for joining aluminum
components.
Risk of corrosion from chemical factors.
Aluminum/steel grinding dust from adjoining work This results in surface corrosion. Erection of
areas. protective barriers.
1.3 Machining properties
MACHINING PROPERTIES
Properties of aluminum compared with steel Effects
Aluminum parts are magnetically neutral. Attachment with magnetic tools/working aids is not
possible.
Elasticity is only 1/3 as high. Convertibility is limited in comparison with steel.
Elongation failure is approx. 50% slighter.
Overstretching the material results in strain-
hardening and an increased tendency of cracking.
Electrical conductivity is almost 4 times higher. Electric welding procedures require different
equipment (MIG welding).
Material expansion during heating is twice as high. The material expands more markedly. Shorter heat
treatment is necessary for removing dents.
Thermal conductivity is 3 times higher. Heat is drained more quickly. Adjoining working
areas are affected more heavily e.g. during welding.
Microstructural change between 200°C and 250°C. Elongation characteristics and thus plasticity are
improved.
Strength is reduced.
IMPORTANT:
No heat treatment when working on the vehicle
structure! Temperature cannot be monitored to
sufficiently exact levels in garages.
Aluminum shows no annealing colors. The melting point is 650°C. Once the melting
temperature has been reached, the material begins to
flow without any further indications.
The temperature can only be estimated by means of
2007 BMW 335i
the paint coloring and the surface warpage.
IMPORTANT:
Do not use thermal applicators. Not suitable for
garage use because the paint runs too quickly.
1.4 Mounting
MOUNTING
Characteristic features of aluminum Special measures
Corrosion (ageing) in damp environments. Store aluminum parts in a dry place.
Contact corrosion in event of contact e.g. with steel Always store aluminum parts separately or in
parts. isolation from steel parts.
Susceptibility to paint infiltration. Do not damage protective surface layer since this
would cause oxidation.
Failure to comply with this requirement would
result in more painting work.
41 00... NOTES ON ADHESIVE K1
IMPORTANT: Note the following information before starting to apply adhesive!

 Processing instructions on glue cartridge
Storage
Dry at 15°- 25°C.
Shelf life
The glue cartridge is marked with a date.
Do not use the adhesive after this date.
The PRE-TREATMENT depends on the material to be bonded and its coating.
Required cartridge gun
Overview of glue cartridge guns
Do not use any compressed-air-operated cartridge guns.

2007 BMW 335i
Preparing the glue cartridge
Opened glue cartridges may be used again before the expiry date as long as a new mixing tube is used.
The working temperature of glue cartridge must be at least 20°C.
Insert glue cartridge into cartridge gun, remove cap and allow both adhesive components to emerge. Strip
adhesive components uniformly and attach mixing tube. Only use mixing tubes supplied with glue cartridge.
Approx. Allow approx. 10 cm of mixed adhesive to emerge and then apply the mixed adhesive first on one side
of the bonding surface.
Pot life of mixed adhesive approx. 2 hours. A change of mixer is only necessary if over a period of 1 hour no
material has flowed through the mixer.
Adhesive application
Read the vehicle-specific repair instructions to determine the thickness and positioning of the adhesive bead.
After applying the adhesive, check whether an adhesive component has emerged at the back of the glue
cartridge. If yes, break off the bonding procedure. Clean new part. Use new glue cartridge. Contact national
hotline.
Remove contamination caused by adhesive residue immediately.
Hardening time
Do not move the vehicle before the adhesive has hardened.
If the adhesive cannot be pressed in any further with a fingernail, the vehicle may be moved (without engine
force) for further processing applications (e.g. painting).
Vehicle strength for driving applications is achieved after:
48 hours at min. 15°C object temperature (corresponding to approx. 18°C room temperature).
When using radiant heaters, make sure that the object temperature does not exceed 85°C. Excessively high
temperatures will destroy the adhesive.
Disposal of adhesive
Hardened adhesive is disposed of as normal waste.

2007 BMW 335i
Empty glue cartridges are disposed of as normal waste.
Non-hardened adhesives and mixtures of adhesive and solvent and the like must be disposed of as hazardous
waste.

Storage
Dry at 15°-25°C.
Shelf life
See vehicle-specific repair instructions
CARTRIDGE GUN 81 43 2 159 881/883

2007 BMW 335i
Fig. 14: Identifying Cartridge Gun With Speed Control

1. Speed control
IMPORTANT: Set speed control (1) to interval stage 3 to prevent overloading the cartridge
gun.
Working life of adhesive is approx. 20 minutes.
IMPORTANT: At working temperatures above 30°C, the working life of the adhesive is
reduced to 10 minutes!
Approx. Allow approx. 10 cm of mixed adhesive to emerge and then apply the mixed adhesive first on one side
of the bonding surface.
hotline.

2007 BMW 335i
Hardening time
waste.

Storage
Dry at 15°- 25°C.
Shelf life

2007 BMW 335i
Do not prepare the glue cartridge until just before applying the adhesive.
Pot life of adhesive is approx. 10 minutes at 25°C.
Before starting to apply adhesive, allow approx. 1 mixing tube length of mixed adhesive to emerge. Only then
apply the mixed adhesive to one side of the bonding surface.
Opened cartridges may be used again before the expiry date as long as a new mixing tube is used.
2-component adhesive application
Hardening time
Adhesive disposal
waste.

Storage
Dry at 15°- 25°C.

2007 BMW 335i
Shelf life
Do not prepare the glue cartridge until just before applying the adhesive.
Working life of adhesive is approx. 10 minutes.
Before starting to apply adhesive, allow approx. one half mixing tube length of mixed adhesive to emerge. Only
then apply the mixed adhesive to one side of the bonding surface.
2-component adhesive application
Hardening time
The bonded connection will be resistant after 30 minutes.
waste.

2007 BMW 335i

Storage
Dry at 15°- 32°C.
Shelf life
Before starting to apply adhesive, allow approx. 1 mixing tube length of mixed adhesive to emerge. Only then
apply the mixed adhesive to one side of the bonding surface.
Pot life of adhesive is approx. 60 minutes at 23°C.
2007 BMW 335i
hotline.
Hardening time
Do not move the vehicle before the adhesive has hardened
If the adhesive cannot be pressed in any further with a fingernail, the vehicle may be moved (without engine
force) for further processing applications (e.g. painting).
The procedure may be accelerated by using a radiant heater. Let the adhesive harden for 30 minutes at 85°C.
The component can then be processed in the joint areas.
Vehicle strength for driving applications is achieved after:
24 hours at a minimum object temperature of 23°C.
When using radiant heaters, make sure that the object temperature does not exceed 85°C. Excessively high
temperatures will destroy the adhesive.
waste.
41 00... NOTES ON CLEANING AGENT R1
Use only cleaning agent R1, as other cleaning agents cab be emollient/moistening or may start to dissolve the
cathodic dip paint primer.
41 00... NOTES ON REPAIRING THREADS

2007 BMW 335i
IMPORTANT: Install Helicoil thread inserts so that they are flush with the original thread.
NOTE: Damaged threads may be repaired with Helicoil thread inserts. Comply with the
Procedure described in the example.
SCREW/BOLT SPECIFICATION
Screw/bolt fastening
Screw/bolt connection Vehicle point(s) Helicoil thread insert
Front axle carrier to E46 All M12x1.5x18
engine carrier E53 All M12x1.5x18
E60, E61, E63, E64 Front, middle See repair elements
Rear M12x1.5x18
E65, E66, E67 All M12x1.5x18
E70 All M14x1.5x21
E83 All M12x1.5x18
E85, E86 All M12x1.5x18
E81, E82, E87 All M12x1.5x18
E90, E91, E92, E93 All M12x1.5x18
Bracket, control arm, to E46, E85, E86 All M10x1.5x15
engine carrier
Rear axle carrier to frame E46 All M12x1.5x18
side member E53 All M14x1.5x21
E60, E61 All M14x1.5x21
E63, E64 All M14x1.5x21
E65, E66, E67 All M14x1.5x21
E70 All M14x1.5x21
E83 All M12x1.5x18
E85, E86 All M12x1.5x18
E81, E82, E87 All M12x1.5x18
E90, E91, E92, E93 All M12x1.5x18
Bearing block, trailing E46, E83, E85, E86 All M12x1.5x18
arm to side member
41 00... OPENING ADHESIVE BONDS
1. Opening spot-weld bonds

 Set punch mark in center of weld spot. Set 8 mm dia. weld spot drill bit on punch mark and drill
through top metal sheet.
Or open weld spot with Vario Drill spot welding cutter.
NOTE: Because the weld spots may have surface-hardened, grind them if
necessary with an angle grinder and paper grinding disk.
2007 BMW 335i
 Heat connecting flange with a hot air blower.
CAUTION: Extract vapors and gases.
 Release connection flange with chisel.

 Grind off residual adhesive from connecting flange.
CAUTION: Wear a grinding dust mask.
2. Opening adhesive bonds on aluminium parts

 Remove Punch Rivets Or Blind Rivets.
 Roughly cut out damaged component. The component can be peeled with the aid of pliers. If
necessary, heat bonding flange with hot air blower.
CAUTION: Heat only the damaged component with a hot air blower.
Extract vapors and gases.
 Grind off residual adhesive from connecting flange.
CAUTION: Wear a grinding dust mask.
If engine carrier part replacement on the GRAV is carried out repeatedly, cut the damaged part at

the existing cutting line. Heat bonding flanges with a hot air blower. Peel off remnants of expander
elements with pliers.
3. Opening adhesive bonds on carbon-fibre-reinforced plastic parts
Procedure is described in detailed in the relevant repair instructions.
41 00... OPENING BRAZED JOINTS
The "Bonding and Riveting" repair method involves replacing the watertight brazed joint with adhesive.
This gives rise to a new procedure for opening brazed joints.
Grind brazed seam with a belt grinder. This keeps the influence of heat in the area around the brazed seam as
small as possible.
IMPORTANT: Never use a gas flame.

2007 BMW 335i
All traces of brazing solder do not have to be removed.
Do not grind body panels thin.
41 00... OPENING RIVETED JOINTS
Different rivet types are used on BMW vehicles.
1. Opening blind rivets
1.1 Opening blind rivets (N1 and N2)
Grind off blind rivet head with a belt or angle grinder. Do not grind off base material. Remove rivet remnants
with a drift punch.
1.2 Opening blind rivets (N3 and N6)
Drill out blind rivet head with a 5 mm dia. drill bit. Do not damage base material. Remove rivet remnants with a
drift punch.
2. Opening punch rivets
2.1 Opening punch rivets by extraction
This procedure is used on the reduced-weight aluminum front end.
Recommended tools and equipment:
 Stud welding apparatus with gas bottle containing inert gas (82 % argon, 18 % CO 2 ).
 Stainless steel stud (sourcing reference via BMW Parts Department picture board Aluminum and
steel/bonding and welding)
 Universal riveting tool
Grind off paint and dark grey coating of punch rivets.
Position bolt centrally on the rivet and weld on vertically. The area in which the bolts are welded on should be
between the two grounding terminals. Position both terminals, if possible, on the top side of the metal plate on
which the rivet is located.
Extract bolt with welded-on rivet using universal riveting tool. Use a large plastic nose piece if not otherwise
specified in the repair instructions. Check plastic nose piece prior to use for wear.
Plastic nose piece must rest on sheet metal all round; if necessary, grind off plastic noise piece in collision area.
Do not push riveting tool forcefully onto special-steel bolts.
Do not use riveting tool to bend special-steel bolts.

2007 BMW 335i
Pay particular attention to central positioning of the bolt when using the small plastic mouthpiece.
Follow the equipment manufacturer's instructions for use.
2.2 Opening punch rivets by drilling out
Drill out rivets with a 6 mm dia. carbide drill bit.
Punch rivets can be drilled out on both sides. When drilling from the protruding rear side, spot-drill the rivet
shank only and remove the rest with a rivet punch.
Use a drift punch to remove punch rivet remnants in the aluminum (risk of corrosion).
Clean vehicle to remove chips (risk of corrosion).
41 00... OPENING WELDED CONNECTIONS
1. Opening weld spots (resistance pressure spot welding):

 Set punch mark in center of weld spot. Set 8 mm dia. weld spot drill bit on punch mark and drill
through top metal sheet.
Or open weld spot with Vario Drill spot welding cutter.
NOTE: Because the weld spots may have surface-hardened, grind them if
necessary with an angle grinder and paper grinding disk.
2. Opening laser weld seams:

 Place angle grinder with grinding disk on laser weld seam and grind through top metal sheet. Be
careful not to cut through and damage sheet metal underneath.
41 00... OVERVIEW OF ADHESIVE CARTRIDGE GUNS
Adhesive gun 83 19 2 149 522
Usable for adhesives K4, K5a.
Including insert 1:1 and 2:1.

2007 BMW 335i
Fig. 15: Identifying Adhesive Gun (83 19 2 149 522)

Adhesive gun 81 49 0 443 166
Usable for adhesive K3.
Fig. 16: Identifying Adhesive Gun (81 49 0 443 166)

Adhesive cartridge gun 81 49 2 159 881/883
Usable for adhesives K1, K2, K5b, sealant D1 and window glass adhesive.
2007 BMW 335i
Fig. 17: Identifying Adhesive Cartridge Gun (81 49 2 159 881/883)

Adhesive cartridge gun 83 30 0 494 836
Usable for structural foam HS2.
NOTE: Special tool number 41 3 010
Fig. 18: Identifying Adhesive Cartridge Gun (83 30 0 494 836)

41 00... OVERVIEW OF CONSUMABLES (ELECTRONIC PARTS CATALOGUE)
1.0 Adhesives
ELECTRONIC PARTS CATALOGUE REFERENCE

Part number,
Designation, repair Designation, Electronic Electronic Parts
instructions Parts Catalogue Catalogue Remarks
Adhesive K1 Body adhesive K1 83 19 0 413 015 195 ml
2007 BMW 335i

Adhesive K3 Body adhesive K3 83 19 0 417 144 2 x 300 ml
Adhesive K5a Body adhesive K5a 83 19 2 158 654 50 ml
Adhesive K5b Body adhesive K5b 83 19 2 157 298 195 ml
Adhesives K5a and K5b are the same adhesive in different package sizes.
1.1 Primer

Part number,
Primer P1 Primer P1 83 19 0 302 556 50 ml
Primer P2 Primer P2/Gas cartridge 83 19 0 302 555 50 ml
1.2 Cleaning agent

Part number,
Cleaning agent R1 Cleaning agent R1 83 19 2 157 286 125 ml
Cleaning agent R2 Cleaning agent R2 83 19 0 417 324 500 ml
Cavity sealing wax Cavity sealing wax 83 12 0 390 086 500 ml
remover remover
1.3 Fillers

Part number,
Metal filler 2C metal filler 83 19 2 154 175
US version:
83 19 2 163 602
Asian version:
83 19 2 163 603
2.1 Rivets

Part number,
2007 BMW 335i
Blind rivet N1 Blind rivet N1 83 19 0 301 414 dia. 6.5 mm; clamping
Hemlock 813 range 2.8-4.8 mm
Blind rivet N2 Blind rivet N2 83 19 0 301 419 dia. 6.5 mm; clamping
Hemlock 815 range 4.8-6.8 mm
Blind rivet N3 Blind rivet N3 83 19 0 301 421 dia. 4 mm; clamping
range 1-3 mm
Punch rivet N4 Punch rivet N4 83 19 2 158 080 dia. 3 mm; length 4 mm
Punch rivet N5 Punch rivet N5 83 19 2 158 079 dia. 5 mm; length 5 mm
Blind rivet N6 Blind rivet N6 83 19 2 158 655 dia. 4 mm; clamping
range 3-5 mm
2.2 Plastic nuts

Part number,
Cap nut Plastic nut 51 16 1 943 122 Dia. 18 mm
Cap nut Clip nut 07 14 7 139 081 Dia. 30 mm
3.0 Primer

Part number,
Primer HS-AK multibase filler 51 91 0 432 612 200 ml; pot life 5 hours
2K spray
Primer EP base filler 2K spray 51 91 0 432 615 200 ml; pot life 8 hours
Welding primer INOX spray welding 83 40 0 409 992 500 ml
primer
4.0 Sealant

Part number,
Sealant D1 Seam sealing 83 42 0 428 349 310 ml
Sprayable sealant
5.0 Cavity preservation

Part number,
2007 BMW 335i

Cavity sealant Cavity sealant spray 83 42 0 428 190 400 ml
Cavity sealant Cavity preservation 83 42 0 428 348 1000 ml
6.0 Cavity foam

Part number,
Cavity foam HS1 Cavity foam 83 42 9 410 694 400 ml
Structural foam HS2 Structural foam 83 19 0 007 361 420 ml
7.0 EMC screw (electromagnetic compatibility)

Part number,
EMC screw Screw 83 19 0 301 639 SF Plus M5x15
8.0 Twist drill

Part number,
Drill bit Twist drill 83 19 2 166 461 4.2 x 119 mm
41 00... POSITION OF SHAPED PARTS FOR CAVITY BULKHEAD (COUPE)
Cavity sealing is carried out in specific body areas in order to reduce internal noise and to reduce condensate.
To do this, shaped parts are inserted in the cavities. These shaped parts adapt themselves optimally due to
heating of the body to approx. 180°C by expansion to the shape of the cavities.
Because it is not possible to heat the body to this extent for a body repair, a Different Procedure has been
specified for this situation.
2007 BMW 335i
Fig. 19: Positions Of Shaped Parts For Cavity Bulkhead

41 00... POSITION OF SHAPED PARTS FOR CAVITY ACOUSTIC BAFFLE (CONVERTIBLE)
Cavity sealing is carried out in specific body areas in order to reduce internal noise and to reduce condensate.
To do this, shaped parts are inserted in the cavities. These shaped parts adapt themselves optimally due to
heating of the body to approx. 180°C by expansion to the shape of the cavities.
Because it is not possible to heat the body to this extent for a body repair, a different procedure has been
specified for this situation.
Fig. 20: Identifying Specific Body Areas

41 00... PROCEDURE FOR FOLDING ROOF AFTER AN ACCIDENT (CONVERTIBLE)
The folding roof may be under tension after the vehicle has incurred damage following an accident. Moving the
folding roof by hydraulic means may result in irreparable damage. For this reason, the folding roof may only be
moved manually until the damaged has been repaired.
2007 BMW 335i
IMPORTANT: It is not possible to check the correct operation of the folding roof on the
damaged vehicle.
Different procedures are required, depending on the degree of damage which the vehicle has incurred. The
repair instructions for emergency actuation describe only the complete sequences for manually opening and
closing the folding roof.
When removing the roof module and/or the rear end module, it is possible to move the folding roof manually
into the necessary intermediate positions in each case.
WARNING: Risk of injury due to the heavy weight of the folding roof!
Since the hydraulic system may have to be depressurized during manual
movement of the folding roof, there is an increased risk of injury by
trapping. Always secure the folding roof adequately against unintentional
movement.
After body repairs to the vehicle
All the folding roof components screwed/bolted to the body are precisely screwed/bolted to the vehicle at the
factory by means of gauges. This affects above all the base plates and mounting brackets of the roof and rear
end modules. To minimize extensive adjustment work after a body repair as much as possible, only remove
those components which are screwed/bolted to a damaged body part.
 Gauge the BASE PLATES only after a body repair to the cowl panel.
41 00... PUNCH RIVETS
The "Bonding and Riveting" repair method involves the use for the first time of punch rivets in the repair. This
requires new tools and procedures.
The punch rivets are matched in size to the material thickness and quality used at the respective connection
point.
 Punch rivet tool
Setting punch rivets
 Refer to the vehicle-specific repair instructions for the punch rivet size.
 Mark the positions of the rivets on the vehicle. Set punch rivets at roughly equal spacings.
Punch rivets do not require a predrilled hole. They are pressed directly into the full material.
 Insert punch rivet in riveting die. Position punch rivet tool on sheet metal parts to be riveted.
Riveting direction:
2007 BMW 335i
Always from new part to used part.
Deviations are specified in the vehicle-specific repair instructions.
 Rivet punch rivets with punch rivet tool. In the meantime clean riveting die and matrix if fouled with
adhesive.
 Seal punch rivets in moist area (e.g. wheel arch or carrier support) on both sides with SEALANT D1
(risk of corrosion).
 Seal cavities after painting vehicle with CAVITY SEALANT (risk of corrosion).
41 00... QUALITY STANDARD
 The overall requirements relating to a vehicle can only be implemented by including "all" components.
This applies in particular to the body. With regard to an optimum crash result, it is necessary to maintain
the structural measures.
It is absolutely essential to observe the procedures set out in the repair instructions. Any deviation from
these procedures will only be permitted after prior consultation with and approval by BMW. Should you
have any questions, please contact the country-specific Hotline.
The use of non-approved repair steps or tools may have serious consequences for the structure of the
vehicle (e.g. in the event of a crash). In the end, this can result in safety and product liability risks which
cannot be calculated.
Corrosion protection measures during and after repairs are absolutely essential to maintain the value of
the vehicle.
 Use only genuine BMW parts and approved auxiliary devices, materials and operating flu ids when
carrying out repairs.
41 00... RIVETING ALUMINIUM PARTS
 Stud welding apparatus with gas bottle containing inert gas (82 % argon, 18 % CO2).
 Stainless steel stud
 Universal riveting tool
 Hand riveting tool for blind rivet nuts and blind rivet bolts.
2.1 Extracting punch rivets:
 Grind off paint and dark grey coating of punch rivets.

 Position bolt centrally on the rivet and weld on vertically. The area in which the bolts are welded on
should be between the two grounding terminals. Position both terminals, if possible, on the top side of the
metal plate on which the rivet is located.
 Extract bolt with welded-on rivet using universal riveting tool. Use a large plastic nose piece if not
2007 BMW 335i
otherwise specified in the repair instructions. Check plastic nose piece prior to use for wear.
 Plastic nose piece must rest on sheet metal all round; if necessary, grind off plastic noise piece in collision
area.
Do not push riveting tool forcefully onto special-steel bolts.
Do not use riveting tool to bend special-steel bolts.
 Pay particular attention to central positioning of the bolt when using the small plastic mouthpiece.
 Follow the equipment manufacturer's instructions for use.
2.2 Drilling out punch rivets:
Only if extraction proves repeatedly unsuccessful or the rivet cannot be accessed with the universal riveting
tool.
 Drill out rivets with a 6 mm dia. carbide drill bit.

 Punch rivets can be drilled out on both sides. When drilling from the protruding rear side, spot-drill the
rivet shank only and remove the rest with a rivet punch.
 Use a drift punch to remove all punch rivet remnants in the aluminium (risk of corrosion).
 Clean vehicle to remove all traces of chips (risk of corrosion).
2.3 Drilling out blind rivets:
Only when a part is repeatedly replaced.
 Drill out rivet head only with 6 mm dia. metal drill bit. Knock out rivet remnants with a drift. Use
existing 6.7 mm hole for blind rivet.
 Clean vehicle to remove all traces of chips and rivet remnants (risk of corrosion).
3.0 Blind riveting in conjunction with bonding
 The standard punch rivets are always replaced by blind rivets in conjunction with bonding.
 The required strength of the connection is only achieved through a combination of bonding and riveting.
4.0 Setting blind rivets:
 Refer to repair instructions for rivet size (size 13 or size 15 with 6.5 mm dia. or 4.0 mm dia.).
 Position blind rivets in the same locations as the extracted punch rivets. Exceptions are described in the
relevant repair instruction. If necessary, carry over the positions of the rivets to the new component.
 Drill holes (4.2 mm dia. for 4 mm rivet and 6.7 mm dia. for 6.5 mm rivet).
 Apply adhesive.
 Insert blind rivet. The riveting direction is the same as the line of vision in the picture shown in the repair
instruction (e.g. from wheel arch into engine carrier).
2007 BMW 335i
 Universally rivet blind rivet with riveting tongs.

 Seal blind rivet with PU sealing material (risk of corrosion).
 Seal cavities with preserving agent (risk of corrosion).
5.0 Setting blind rivet nuts and blind rivet bolts:
 Standard stud welding is always replaced by blind rivet bolts.

 Drill holes (0.2 mm larger than the outside diameter of the blind rivet nuts or blind rivet bolts).
 For corrosion reasons, blind rivet nuts and bolts must have a special coating.
Use the blind rivet nuts and bolts supplied in the case of the manual riveting tool for steel only!
 Insert blind rivet nuts or bolts and tighten down with the riveting tool.
 It will no longer be possible to set a blind rivet nut if the drilled hole is too big. In this case, set a clip nut.
This nut tightens itself automatically when screwed to the component.
 Seal blind rivet nuts and bolts with PU sealing material (risk of corrosion).
41 00... RIVETING STEEL PARTS
 Manual riveting tool for blind rivet nuts and bolts.
2.0 Setting blind rivet nuts and blind rivet bolts:
 Blind rivet nuts and bolts must have a special coating for corrosion reasons.
41 00... SAFETY AT WORK
1.1 Working with aluminum dust:

 Wear a fine dust mask.
 E52 only: Use an explosion-proof extractor system.
 Note national regulations.
1.2 Removing sealing materials

 Hydrochloric acid is created when PVC sealing material is heated to temperatures in excess of 180°
C.
 Remove PVC sealing material with a rotating wire brush only or heat material with a hot air blower
to max. 180°C and remove with a spatula.
2007 BMW 335i
 Ensure that all enclosed areas are well ventilated or are provided with direct extractor facilities.
1.3 Arc welding and brazing:
IMPORTANT: The extremely bright arc during welding may cause serious injury to the
eyes if appropriate protective measures are not taken.
 Use a special welding screen for the relevant welding process (MAG or MIG).
 Partition off the work bays with beam protection screens.
 Use a welding-emissions extractor facility.
 The welder must wear protective clothing and gloves which are suitable for welding (i.e.
flameproof).
 A fire extinguisher must be located within reach of the welding area.
 Do not carry out any welding work in the proximity of a fuel tank e.g. when it is installed.
1.4 Working with adhesive products (adhesives, cleaning agents, primers etc.):
IMPORTANT: Handling adhesives can trigger off allergic skin and breathing reactions.

 Avoid direct contact with eyes and skin.
 Wear protective goggles, protective gloves and if necessary an apron.
 Ensure that all enclosed areas are well ventilated or are provided with direct adhesive fume
extractor facilities.
 Work clothing which has been contaminated with adhesive or solvent must be changed
immediately.
 After finishing work, wash your hands and apply protective skin cream.
 Always keep an eye bath on hand, change the water regularly (once a month).
 Store adhesive products in a secure cabinet only.
 Keep adhesive products away from naked flames and other ignition sources.
 Protect adhesive products against strong heat sources and direct sunlight.
First Aid:
In the event of eye contact, flush immediately with running water for approx. 10-15 minutes and, if necessary,
visit eye specialist.
In the event of skin contact and where applicable an allergic skin reaction, clean the affected areas immediately
with soap and water and then apply silicone-free skin cream. If necessary, consult a doctor.
If an adhesive product is swallowed, rinse mouth/parts of mouth thoroughly with running water. Drink 1-2
glasses of water. Do not induce vomiting. Consult a doctor.
2007 BMW 335i
If adhesive fumes are inhaled, ensure a constant supply of fresh air, keep calm, keep respiratory tracts
unobstructed and consult a doctor.
41 00... SPOT-WELD BONDING STEEL PARTS
IMPORTANT: Comply with the following:
SAFETY REGULATIONS
HANDLING ELECTRICAL/ELECTRONIC EQUIPMENT
AIRBAGS AND RESTRAINT SYSTEMS
WELDING STEEL PARTS
 The spot-weld bonding process is used starting from the E65 to increase vehicle rigidity. In partial
bodywork areas, a 1-component adhesive is applied to the spot flanges and this is followed by resistance
pressure spot welding. The adhesive is hardened only after the paint drying process (at approx. 180°C).
 In the case of repairs, adhesive is not applied to the spot flanges. The number of welding spots is doubled
as a substitute for the omitted adhesive.
 The following processes are used as a substitute for spot-weld bonding:
 MAG welding (M etal A ctive G as welding)
 Resistance pressure spot welding (referred to in the following and in the repair instructions as spot
welding).
 Adhesive is not applied between the spot flanges on new parts in the case of 2- or multi-sheet joints.
Areas which cannot be reached by the spot-welding tongs can be joined by MAG spot welding. The
number of welding spots is doubled as a substitute for the omitted adhesive.
Exceptions (e.g. E65) are described in the relevant repair instructions. Apply welding spots to existing
welding spots on new part. This is necessary because the adhesive between the spot flanges of the new
part acts as an insulator.
CAUTION: Extract smoke and fumes during welding work.
41 00... STAMPING VEHICLE IDENTIFICATION NUMBER
Special Tools Required:
 41 0 000
 41 1 140
 41 1 141
2007 BMW 335i
 41 1 142
NOTE: If the stamped vehicle identification number is removed during repair work, it
must be stamped in again.
Read and comply with General Information.
 Remove Front Right Spring Strut

 Remove rubber base from guide plate 41 1 141
Special tool kit 41 1 140 for stamping vehicle identification number consists of:
Guide plate 41 1 141
Counter-plate 41 1 142
Fig. 21: Special Tools (41 1 141) And (41 1 142)

Position counter-plate 41 1 142 at bottom on spring strut dome.
Position guide plate 41 1 141x at top on spring strut dome and tighten bolts (1) by hand.
2007 BMW 335i
Fig. 22: Bolts, Special Tools (41 1 141) And (41 1 142)
Tighten bolt (1) until counterholder 41 1 142 rests on spring strut dome.
Fig. 23: Special Tool (41 1 142) And Bolt

Tighten screws (1).

2007 BMW 335i
Fig. 24: Screws, Special Tools (41 1 141) And (41 1 142)
NOTE: The illustration is a schematic representation and is to be applied to the

relevant vehicle type.
Insert punch numbers 41 0 000 (1) individually in to guide plate (2) and stamp vehicle identification number.
Fig. 25: Punch Numbers (41 0 000) And Guide Plate

NOTE: In the event of component or body replacement by the workshops/garages,

clearly delimit the vehicle identification number at front and rear by stamping a
"+" in place of the BMW emblem.
Note national regulations.
41 00... STRAIGHTENING STEEL PARTS
1.0 Recommended tools

2007 BMW 335i
Only use those tools designed for steel repairs.
2.0 Straightening outer shell
 "Cold" straightening: Press dents out from their center and smooth in an inwards direction with gentle
taps.
In the case of small, soft dents (hail and parking damage), this is also possible without damaging the
paintwork. This work requires a special tool and a trained worker.
 "Hot" straightening: Heat dents in their central point only with a gas flame until bright red hot. Then
quench the material with a wet cloth.
 Stud welding can be used in the case of damage where access is only possible from one side. Weld on the
stud in the middle of the damaged area. The steel pin or shim is driven out using a hammer until the
depression is removed. The stud, pin or shim is then ground or twisted off.
 Avoid cracking.
 Avoid hardening and overstretching.
 Avoid heating and overheating the outer shell over large areas.
 If, after steel parts have been straightened, the surface shows no dents larger than 2 mm, these dents may
be touched up with knifing filler.
Dents larger than 2 mm must be treated with filling solder.
NOTE: Only applicable within the European Union!
European used-car regulations prohibit the use of tin containing lead in motor vehicles introduced after
01.07.2003!
 For safety vehicles, follow the special notes and in formation in the repair instructions.
3.0 Straightening structure
 Repairs affecting the mounting points of assemblies and chassis/suspension components must be carried
out on the straightening bench with the matching straightening attachment set or specification sheet for
the vehicle.
Straightening attachments and specification sheets are also available for the top section, e.g.: door pillars,
convertible top mounts, cowl, rear lid hinges, etc.
 Check windshield and rear window apertures for curvature by inserting the original glass.
 Take the gap dimensions for doors, engine hood and rear lid from the vehicle-specific gap dimension
diagram.
 Bearing body components such as e.g. engine carriers, door pillars, frame side members etc. with
deformations which can no longer be returned to their original shape by "cold straightening" must be
replaced.
2007 BMW 335i
Heating bearing body components for better reshaping is not permitted!
Failure to comply with this requirement would result in a loss of original strength of up to 40 %.
 High-strength and super-high-strength steel plates as a rule cannot be reshaped. Reshaping only serves as
a preparatory measure to replacing the component in order to achieve optimal joining of the connection
points.
 The body must be anchored as follows for reshaping:
If using vehicle-specific/universal straightening attachment sets (Carbench/ Celette), it is necessary to

secure the body additionally with 4 retaining clips to the spot flange of entrance or to the 4 jacking
points. The spot flange (if available) is to be preferred.
If using universal electronic or mechanical straightening systems (Car-O-liner/ Celette), it is necessary to

secure the body with 4 retaining clips to the spot flange of entrance or to the 4 jacking points. The spot
flange (if available) is to be preferred. In addition anchor at least 2 points with the securing set.
Failure to comply with these instructions will result in damage to the body during reshaping in non-
damaged areas. Vehicle-specific straightening attachments and universal mounts may be damaged.
41 00... USE OF MATERIALS IN OUTER SHELL
The following illustration is a schematic representation of all the body variants.
Apply this illustration to the relevant vehicle.
Fig. 26: Outer Shell Body Components

All components not listed in the table below are composed of established sheet steel qualities.
COMPONENTS MATERIAL CHART

Component Vehicle Material
(1) Side panel, front E52 (Z8) Aluminium
2007 BMW 335i
E60, E61 Aluminium

E63, E64 Plastic (thermoplastic)
E65, E66: Aluminium
E70, E92, E93 Plastic (thermoplastic)
(2) Front door E36/C (M3) Aluminium or steel
E36/2 (M3) Aluminium or steel
E52 (Z8) Aluminium
E63, E64 Aluminium
(4) Side panel, rear E52 (Z8) Aluminium
(5) Engine hood E38 (750i) Aluminium or steel
E46/C (M3) Aluminium
E46/2 (M3) Aluminium
E52 (Z8) Aluminium
E60, E61, E63, E64 Aluminium
E65, E66, E70 Aluminium
E85 (Z4) Aluminium
E92 (M3) Aluminium
(6) Hardtop/ roof E36/C Aluminium
E36/7 (Z3) Plastic (glass fibre / epoxy resin)
E46/C Aluminium
E46/2 (M3 CSL) Plastic (CFK)
E52 (Z8) Plastic (PU)
E85 (Z4) Plastic (SMC)
E63 (M6) Plastic (CFK)
(7) Soft top lid E46/C Magnesium
E64 Plastic (SMC)
(8) Rear lid E46/2 (M3 CSL) Plastic (SMC)
E52 (Z8) Aluminium
E63, E64 Plastic (SMC)
41 00... VEHICLE IDENTIFICATION NUMBER, GENERAL
The vehicle identification number must be stamped with a special tool. There are different special tool numbers
and stamping procedures for the various vehicles. Refer to the relevant repair instructions.
In repair work, the vehicle identification number is always stamped into a replacement vehicle identification
number surface. The replacement surface is usually situated under the original VIN surface.
The IGEF number (bodyshell number) is omitted when the wheel arch is replaced.
In the event of component or body replacement by the BMW garages/workshops, clearly delimit the vehicle
identification number at front and rear by stamping a + in place of the BMW emblem.
2007 BMW 335i
If a VIN is stamped in to the replacement surface in addition to the original VIN (e.g. if the original VIN has
been tampered with), the following applies: The original VIN must be crossed out. To do so, stamp the letter I
from the punch digits lengthways through the original VIN.
IMPORTANT: Do not use an angle grinder in conjunction with a cutting disk!
The protective film used as standard is omitted after the VIN has been manually stamped in. Paint area in
accordance with BMW Painting Handbook. Ensure that layer thicknesses are small.
Observe country-specific regulations.
41 00... REINFORCEMENT PLATE (BONDED)
In the case of a partial replacement piece, a body component is cut at a point described in the repair instructions.
A reinforcement plate is bonded in to ensure sufficient strength.
Observe notes on REPAIR STAGE 2.
NOTE: The following graphics serve as general illustrations of reinforcement plate

repair work. They apply to sectional repairs to the structure.
Mark component in accordance with measurement a and cut.
Fig. 27: Identifying Component Cutting Dimension

Preparation of new part
Cut new part (1) in accordance with cut on vehicle and if necessary adjust to fit with straightening attachment or
universal mount.
2007 BMW 335i
Fig. 28: Identifying Cutting Position

Make reinforcement plate (1) from trim of new part (2).
Length of reinforcement plate is 80 mm.
Fig. 29: Identifying Reinforcement Plate And New Part Trim Plate
Slide reinforcement plate (1) halfway into component on body and fasten with 2 self-tapping screws (2).
2007 BMW 335i
Fig. 30: Sliding Reinforcement Plate Half-Way Into Body Component

Adjust new part (1) to fit and set 4.3 mm dia. bore holes (2).
Remove new part again.
Release self-tapping screws (3).
Remove reinforcement plate.
Drill out bore holes (3) for screws to 4.3 mm dia.
Deburr all bore holes.
Fig. 31: Identifying Bore Drilling Position

2007 BMW 335i
IMPORTANT: Do not grind new part and body in area of bonding surfaces.
Installing reinforcement plate
Clean all bonding surfaces with cleaning agent R1.
Apply adhesive (1) to reinforcement plate bonding surface.
Carefully slide reinforcement plate half-way into body component (2).
IMPORTANT: When joining reinforcement plate, make sure there is sufficient adhesive on
bonding surfaces.
Fig. 32: Identifying Adhesive On Reinforcement Plate Bonding Surface

Rivet reinforcement plate (1) up to half-way with blind rivets N3 (2).

2007 BMW 335i
Fig. 33: Riveting Reinforcement Plate Up To Half-Way With Blind Rivets N3

Apply adhesive (1) to reinforcement plate bonding surface.
Fig. 34: Identifying Adhesive On Reinforcement Plate Bonding Surface

Install new part (1) with straightening attachment or universal mount and rivet with blind rivets N3 (2).
After adhesive has hardened, flatten adhesive area and seal blind rivets.
2007 BMW 335i
Fig. 35: Installing New Part Using Blind Rivets N3

41 00... REINFORCEMENT PLATE WITH STUD BOLT (BONDED)
A reinforcement plate is bonded in to ensure sufficient strength.
Reinforcement plates are available as new parts and must also be used.
NOTE: The following graphics serve as general illustrations of reinforcement plate

repair work. They are applicable to sectional repairs in the outer skin area.
Overview of reinforcement plates:
1. Reinforcement plate, sill

2. Reinforcement plate, C-pillar
3. Reinforcement plate, universal
4. Reinforcement plate, C- or D-pillar
5. Lock nuts (not pictured)
 Plastic nut 18 mm, part number 1 943 122
 Clip nut 30 mm, part number 7 139 081

2007 BMW 335i
Fig. 36: Identifying Reinforcement Plate Sill, C-Pillar, Universal And C- Or D-Pillar
Mark component in accordance with dimension a and cut.
Fig. 37: Identifying Component Cutting Dimension Mark

The reinforcement plates must if necessary be reworked and cut to size.
Adjust reinforcement plate (1) to fit in component (2) on vehicle.
Make recesses (3) for stud bolts (4) in a semicircular shape.
Diameter of recesses approx. 10 - 12 mm.

2007 BMW 335i
Fig. 38: Adjusting Reinforcement Plate On Components Of Vehicle

Secure reinforcement plate by screwing on lock nuts (1).
Fit new part (2). Make recesses (3) in new part in a semicircular shape.
Diameter of recesses approx. 10 - 12 mm.
Remove reinforcement plate again.
Fig. 39: Fitting New Part

NOTE: Width of joint between new part and component on vehicle approx. 3 - 8 mm (at
least 30 mm flange width per side).
2007 BMW 335i
Plastic nuts should be screwed on once before applying adhesive (no thread in new plastic nut)!
Round off cutting edges
1. On joint by grinding.
2. Component on vehicle
3. New part
Fig. 40: Identifying Cutting Edges, Vehicle Component And New Part
Procedure for using universal reinforcement plate
The universal reinforcement plate needs to be adapted. The plate must be divided if the distance between the
pins is too great.
Dimension a is between 40 and 80 mm depending on the space available.
Secure plates with N4 punch rivets.

2007 BMW 335i
Fig. 41: Identifying Universal Reinforcement Plate Dimension

NOTE: Ensure the rivet is positioned correctly! Rivet head is on the adhesion side!
Rivet the plate to the inside of the flange!
Installing reinforcement plate
Clean all bonding surfaces.
Apply adhesive to reinforcement plate in area (1). Apply more adhesive in the radii to avoid air pockets.
Carefully slide reinforcement plate into component on vehicle and secure by screwing on nuts (2). Screw on
nuts a few turns only.
2007 BMW 335i
Fig. 42: Applying Adhesive To Reinforcement Plate Adhesive

IMPORTANT: When joining reinforcement plate, make sure there is sufficient adhesive on
bonding surfaces.
Apply adhesive to reinforcement plate bonding surface (1). Apply more adhesive in the radii to avoid air
pockets.
Fit new part (2).
Align new part to adjoining component and secure with gripping pliers.
Tighten nuts.
Tightening torque 41 14 1AZ.
IMPORTANT: Check that the transition of the components is OK at the separation point.
Corrections can only be made before the adhesive has hardened. Straightening
at a later stage is not possible.
Fig. 43: Fitting New Part

Concluding tasks at separation point:
After adhesive has hardened:
In area visible to customer:
Cut off stud bolts with bodywork saw.

2007 BMW 335i
Completely remove adhesive residue in joint (1).
Round off sharp edges by grinding.
IMPORTANT: Avoid heating the separation point by excessive grinding.

Reworking by pressing not permitted!
Fig. 44: Identifying Reinforcement Plate Joint

Only the BMW-approved METAL FILLER should be used on the joint.
See METAL FILLER - INSTRUCTIONS FOR USE
Not in area visible to customer:
Examples: The joint is covered by sill trim panel, windows, seals, etc.
Grind off stud bolts and surplus adhesive flush. Do not use metal filler. Paint area as specified in BMW Painting
Handbook.
NOTE: After painting, the joint becomes visible as the adhesive shrinks. This has no
affect on the quality.
41 05 800 RELEASING BONDED FOLDED SEAM CONNECTIONS

2007 BMW 335i
Fig. 45: Removing Bonded Folded Seam Connections

 Remove area (1) of bead edge on wheel arch bend with a one-hand angle grinder and rough grinding
wheel.
 Heat area (2) with hot air blower.
CAUTION: Caution! Extract vapors and gases.
 Release connection flange with chisel.

 Grind adhesive residue (4) off wheel arch connection flange.
CAUTION: Caution! Wear a grinding dust mask.
 Remove remnants of sealing material in area (3).
41 05... REMOVING AND INSTALLING RIVET HEADS
IMPORTANT: Lay out protective mats to protect the interior against debris from the drilled-
out rivets and damage.
2007 BMW 335i
Lay out protective mats in the relevant working area:
 Dashboard
 Entrance area
 Passenger compartment
Fig. 46: Identifying Protective Mats

Described for folding pack holder for head airbag:
Drill off rivet plate down to rivet shank with a 10 mm twist drill bit.
Fig. 47: Drilling Rivet Plate

Described for grab handle holder:
Drill off rivet plate down to rivet shank with a 10 mm twist drill bit.
2007 BMW 335i
Fig. 48: Identifying Grab Handle Holder

Cut off blind rivet shanks down to sheet metal as level as possible.
Fig. 49: Cutting Blind Rivet To Sheet Metal

Deburr remaining rivets with nipper pliers.
Installation note:
Apply primer to paintwork damages on side frame.

2007 BMW 335i
Fig. 50: Removing Rivets With Nipper Pliers

Special tool 72 1 210 for collecting rivet remnants.
Shank (1) of special tool is flexible and can be adapted to the relevant body contours.
NOTE: Insert butyl in collecting tray (2) to secure rivet remnants against falling out.
Fig. 51: Identifying Special Tool 72 1 210 For Collecting Rivet Remnants
Insert special tool 72 1 210 through bore hole in body next to attachment points.
Position special tool from rear on rivet head in cavity.
NOTE: A second person will be needed to help hold the special tool on the rivet head
during the driving-out operation.
Make sure collecting tray is correctly fitted on rivet head.

2007 BMW 335i
Drive out stem with hammer and 6 mm punch.
Carefully feed special tool out of body so that rivet head does not fall out of collecting tray.
NOTE: If the rivet falls out of the collecting tray into the side frame when the special
tool is fed out, this area must be generously filled with foam.
For details of procedure for filling cavities with foam, see further operations.
Use cavity preservation (refer to BMW Parts Department) for foam filling.
Cavity foam (refer to BMW Parts Department) can also be used if necessary.
Fig. 52: Identifying Special Tool On Rivet Head

Fit tube to foam can.
Push the hose in through the pillar holes.
Fill cavity with a filling material.
WARNING: Empty foam can completely onto cardboard and after hardening dispose
of foam and can in residual waste.
Can may burst if not completely emptied.

2007 BMW 335i
Fig. 53: Identifying Foam Can

Overview of rivet gun:
Riveting of gas generator housing and holders for folding pack with rivet gun (refer to BMW Workshop
Catalogue).
The interchangeable head is changed for the different work operations.
Riveting of gas generator housing with:
1. 17/36 nosepiece and short shank
Riveting of holders for folding pack:
2. 17/40 nosepiece and long shank
Fig. 54: Identifying 17/36 Nosepiece And Short Shank - 17/40 Nosepiece And Long Shank
2007 BMW 335i
41 00... WELDING IN REINFORCEMENT PLATE (STEEL PLATE)
A reinforcement plate is welded in to ensure sufficient strength.
Follow notes for Welding steel parts
NOTE: The following illustrations serve as general illustrations of reinforcement plate

repair work. They are applicable to all cutting repairs.
Mark component in accordance with distance A and cut.
Fig. 55: Steel Reinforcement Plate, Cut Mark And Distance (A)
Cut new part (1) in accordance with cut and if necessary adjust to fit with straightening attachment or universal
mount.
Installation:
Adhere to a gap at severance cut of approx. one to max. two material thicknesses in order to ensure welding
with the reinforcement plate and to facilitate a more tolerant fit.
2007 BMW 335i
Fig. 56: Steel Reinforcement Plate New Part Area

Clean inner and outer sides of connecting areas (1) on new part and (2) on body.
Coat inner sides with welding primer.
Fig. 57: New Part And Existing Connecting Area

Drill holes (1) and (2) at distance of 25 mm to each other.
Hole diameter approx. 8 mm.

2007 BMW 335i
Fig. 58: Drill Holes On Existing And New Parts

Make reinforcement plate (1) from trim of new part.
If necessary, make further reinforcement plates.
Length of reinforcement plates is min. 40 mm.
Coat reinforcement plates (1) and (2) on both sides with welding primer.
Fig. 59: New And Existing Reinforcement Plates

Push reinforcement plate (1) into component on body up to half way and plug-weld (2).
2007 BMW 335i
Fig. 60: Reinforcement Plate And Plug-Weld

If necessary, adjust new part (1) to fit with straightening attachment or universal mount and plug-weld (2).
MAG weld joint (3).
Grind and clean weld seam and plug weld spots.
Only visible areas of the outer skin and worn areas on the support carrier must be tinned.
All areas which have covers on the vehicle are not to be tinned.
Fig. 61: New Part, Plug Weld And MAG Weld Joint
European used-car regulations prohibit the use of tin containing lead in motor
vehicles introduced after 01.07.2003!
2007 BMW 335i
41 00... WORKSHOP EQUIPMENT
Minimum workshop equipment requirements in order to ensure the correct and expert performance of body
repairs:
The tools listed below must be used.
WORKSHOP EQUIPMENT
Steel Aluminium
Tool Structure Outer skin Structure Outer skin
Bodywork tool x x
assortment
Aluminium x x
bodywork tool
assortment
Bodywork saw x x
Single-handed x x x x
grinder
Welding spot x x
remover
MAG welding x x
apparatus
MIG welding x (E52 only)
apparatus
Spot welding x x
apparatus
Gas welder x
Straightening system x x
Stud welding x
apparatus
Flame coating set x
Universal riveting x
tool
IMPORTANT: In vehicles from model year 2001, higher-tensile and high-tensile steels are
used in certain areas.
It is essential to check whether the spot-welding apparatus used conforms to

the technical requirements of the currently recommended welding sets. Should
you have any questions, please contact the country specific Hotline.
The use of technically obsolete equipment may have serious consequences for
the structure of the vehicle (e.g. in the event of a crash). In the end, this can
result in safety and product liability risks which cannot be calculated.
2007 BMW 335i
Use and restrictions:
Definition of Recommendation:
All currently recommended spot welding sets comply with the requirements relating to reliable welding of
today's and future BMW Group vehicles. A spot welding unit will loose its recommendation as soon as tests
with materials and material combinations designated for future use in BMW Group vehicles return negative
results (see Group 1 in SPOT WELDING SET RECOMMENDATION). All previous application before the
withdrawal of the recommendation shall remain unaffected.
SPOT WELDING SET RECOMMENDATION

Device designation Manufacturer
Group 1 Devices currently no CR500 Car-O-Liner
longer recommended Spot9000 Tecna
ATL 400V Wielander&Schill
Group 2 Devices currently MIDIspot QSVM9000 Celette
recommended (March 2007) MIDIspot QSVM9000 Elmatech
CR600 Car-O-Liner
Multispot MI-100 Control Elektron
Application options and restrictions of above devices.
APPLICATION OPTIONS AND RESTRICTIONS OF ABOVE DEVICES

Vehicle Group 1 Group 2
E93 x Except A-pillar, B-pillar, sill x
E70 x Except B-pillar x
E64 x Except A-pillar, B-pillar, sill x
NOTE: (March 2007)
All models not listed can be repaired using the Group 1 and Group 2 devices.
41 05 503 INSTALLATION SOLUTION FOR STRAIGHT SHANK/HEXAGON RIVET NUT
Protection measures!

 Wear protective gloves
Straight shank rivet nut:
Failure to comply with these instructions may result in the drill bit slipping and
2007 BMW 335i
causing significant paintwork damage.
1. Mark position of bore and then punch-mark component
Fig. 62: Bore Position And Punch-Mark Component

IMPORTANT: If the determined drill bit diameter is not observed:
 the knurling on the straight shank rivet nut is rendered useless

 the component will be damaged when the straight shank rivet nut is
inserted
Determining suitable drill bit:
Depending on the rivet nut shank diameter, the next drill bit diameter higher (5/10 step) can be used.
E.g. with a shank diameter of 10.1 mm, the 10.5 mm drill bit can be used. The 11.0 mm drill bit must not
be used.
2. Drill bore with determined drill bit and deburr, pilot-drill with a smaller drill bit if necessary
2007 BMW 335i
Fig. 63: Drilling Component

3. Clean component, eliminate paintwork damage if necessary
Fig. 64: Newly Drilled Hole In Component

IMPORTANT: To avoid corrosion, stop chips/debris by means of cavity sealing.
Follow instructions on corrosion protection.
4. Preserving cavity
2007 BMW 335i
Fig. 65: Sealing Cavity

IMPORTANT: Follow manufacturer's operating instructions.
Make sure straight shank rivet nut correctly contacts component.
5. Set straight shank rivet nut with hand rivet gun
NOTE: The pictured tool in Fig. 66 is suitable up to an M8 thread.
Fig. 66: Hand Rivet Gun And Component

Hexagon rivet nut (up to M8 thread):
Make sure hexagon rivet nut correctly contacts component.

2007 BMW 335i
Replace screw after use.
1. Set hexagon rivet nut with hand rivet gun
NOTE: The pictured tool in Fig. 67 is suitable up to an M8 thread

Hexagon rivet nut (from M10 thread):
IMPORTANT: Ensure correct screw length. The complete thread length of the rivet nut must
be used for installation.
1. Insert screw (tensile strength min. 10.9) with body washer into hexagon rivet nut
2. Insert hexagon rivet nut into pre-punched hexagon hole and install by turning screw
NOTE: Rivet nut is upset (screw very difficult to move).
Rivet nut is contracted (screw comparatively easy to move).
Rivet nut is pressed onto the component (screw slowly becomes difficult
to move). Procedure is finished with the fitting of the relevant component
and its tightening torque.
2007 BMW 335i
Fig. 68: Hexagon Rivet Nut And Component

41 0 REPAIR TECHNIQUES, REPAIR STAGE 1
All work which provides only for replacement of screwed/bolted components and planishing operations.
Repair techniques
 Straightening outer skin

 Straightening aluminum parts: see 41 00... STRAIGHTENING ALUMINUM PARTS ON OUTER
SKIN
 Straightening steel parts: see 41 00... STRAIGHTENING STEEL PARTS ON OUTER SKIN
 See METAL FILLER - INSTRUCTIONS FOR USE
 Grinding
 Grinding aluminum components: see 41 00... GRINDING ALUMINUM PARTS
 Grinding steel parts: see 41 00... GRINDING STEEL PARTS
 Steel thread repairs: see 41 00... NOTES ON REPAIRING THREADS
Repairs that are carried out by bonding and riveting without the use of a straightening bench.
Repair techniques
 Removing used part

 OPENING WELDED CONNECTIONS
 OPENING BRAZED CONNECTIONS
 OPENING RIVETED CONNECTION
 Opening bonded connection: see 41 00... OPENING ADHESIVE BONDS or 41 05 800 RELEASING
BONDED FOLDED SEAM CONNECTIONS
2007 BMW 335i
 GRINDING ALUMINUM PARTS

 GRINDING STEEL PARTS
 Sectional repairs
 Reinforcement plate (bonded): see REINFORCEMENT PLATE (BONDED) or REINFORCEMENT
PLATE WITH STUD BOLT (BONDED)
 See METAL FILLER - INSTRUCTIONS FOR USE
 Installing new part
 Notes on consumables: see OVERVIEW OF CONSUMABLES (ELECTRONIC PARTS
CATALOGUE)
 Notes on adhesive: see NOTES ON ADHESIVE K1; NOTES ON ADHESIVE K2; NOTES ON
ADHESIVE K3; NOTES ON ADHESIVE K4 or NOTES ON ADHESIVE K5
 BONDING ON PAINTED SURFACES
 BLIND RIVETS
 PUNCH RIVETS
 Cavity sealing: see INSTALLING A CAVITY BULKHEAD (EXPANDED); INSTALLING A
CAVITY BULKHEAD (NOT EXPANDED) or INSTALLATION OF A CAVITY SEAL WITH
CAVITY FOAM
 EMC SCREWS
 Miscellaneous
 REPAIRING PLASTIC PARTS
 BONDING GLASS PANES
 SETTING BLIND RIVET NUTS AND BOLTS
Repairs that are carried out by bonding and riveting with the use of a straightening bench or welding.
Repair techniques
 Straightening structure
 STRAIGHTENING ALUMINUM COMPONENTS IN STRUCTURE
 STRAIGHTENING STEEL COMPONENTS IN THE STRUCTURE
 Removing used part
 OPENING WELDED CONNECTIONS
 OPENING BRAZED JOINTS
 OPENING RIVETED JOINTS
 OPENING ADHESIVE BONDS
 GRINDING ALUMINUM PARTS
 GRINDING STEEL PARTS
 Sectional repairs
2007 BMW 335i
 WELDING IN REINFORCEMENT PLATE (STEEL PLATE)

 REPLACING LEFT ENGINE CARRIER (PARTIAL REPLACEMENT BEFORE FRONT
AXLE)
Sectional repair (aluminum) with repair element
 Installing new part

 Welding aluminum components
 WELDING AND SOLDERING STEEL PARTS
 SPOT-WELD BONDING STEEL PARTS
 SOLDERING STEEL COMPONENTS
 Notes on consumables: see OVERVIEW OF CONSUMABLES (ELECTRONIC PARTS
CATALOGUE).
 NOTES ON ADHESIVE K1
 Bonding aluminum on steel
 BONDING STEEL PARTS
 BLIND RIVETS
 PUNCH RIVETS
 CAVITY SEALING
 EMC SCREWS.
41 00... REPAIRING PLASTIC PARTS
1.0 General information
 Economic efficiency must always be checked prior to repair.

 Only the following painted USE OF MATERIALS IN OUTER SKIN are approved for repair:
 Bumper trims (exception: E52)
 Sill trims
 Front side panels
 Hardtop/roof
 Convertible top compartment lid
 Rear lid
 Prerequisite for professional repair:

 Only minor deformations (without microcracks, usually visible in the paint)
 Only minor damage, e.g. abrasions, cracks and holes up to 2.5 cm long
 No damage (cracks) to the edge of the component!
CAUTION: The following are not approved for repair:


2007 BMW 335i
 Fuel tanks, reservoirs for liquids/fluids (e.g. windscreen washer unit, brake fluid, coolant expansion
tank, etc.)
 Headlight mountings (pedestrian protection)
2.0 Shaping plastic parts
 Plastic parts can be reshaped using a hot-air blower.

 Microcracks can occur in the plastic if plastic parts are deformed. After the component is reshaped and
then painted, the cracks may become visible again on the surface after a period of time.
 The component must be replaced if microcracks can be identified in the area of deformation.
3.0 Bonding plastic parts
IMPORTANT: Conform with safety precautions . See SAFETY AT WORK and INFORMATION
ON HAZARDS!
 A plastics repair box (sourcing reference: BMW Parts Service) is offered

for cost-effective and time-value-compatible repairs.
 The plastics repair box contains the step-by-step instructions for
repairing plastic parts.
41 00... RIVETING STEEL PARTS
 Manual riveting tool for blind rivet nuts and bolts.
2.0 Setting blind rivet nuts and blind rivet bolts
 Blind rivet nuts and bolts must have a special coating for corrosion reasons.
41 00... SAFETY AT WORK
1.1 Working with aluminum dust
 Wear a fine dust mask.

 E52 only: Use an explosion-proof extractor system.
1.2 Removing sealant

2007 BMW 335i
 Hydrochloric acid is created when PVC sealing material is heated to temperatures in excess of 180°C.
 Remove PVC sealant with a rotating wire brush only or heat material with a hot air blower to max. 180°C
and remove with a spatula.
 Ensure that all enclosed areas are well ventilated or are provided with direct extractor facilities.
1.3 Arc welding and brazing
IMPORTANT: The extremely bright arc during welding may cause serious injury to the eyes if
appropriate protective measures are not taken.
 Use a special welding screen for the relevant welding method (MAG or MIG).
 Partition off the work bays with beam protection screens.
 Use a welding-emissions extractor facility.
 The welder must wear protective clothing and gloves which are suitable for welding (i.e. flame-proof).
 A fire extinguisher must be located within reach of the welding area.
 Do not carry out any welding work in the proximity of a fuel tank e.g. when it is installed.
1.4 Working with chemical products (adhesive, cleaning agents, fillers, etc.)
Heed the manufacturer's material safety data sheets.
IMPORTANT: Handling chemical products may result in allergic skin and breathing reactions.
 Do not eat, drink or smoke while working with these products.

 Avoid direct contact with eyes and skin.
 Wear safety goggles, protective gloves and if necessary an apron.
 Ensure that all enclosed areas are well ventilated or extract fumes directly.
 Use a breathing apparatus with a suitable filter type when ventilation is insufficient.
 Wear impermeable protective clothing.
 Immediately change contaminated work clothing.
 After finishing work, wash your hands thoroughly and apply protective skin cream.
 Always keep an eye douche on hand, change the water regularly (once a month).
 Store bonding products in a secure cabinet only.
 Keep bonding products away from naked flames and other ignition sources.
 Protect bonding products against strong heat sources and direct sunlight.
First Aid
If product comes in contact with eyes, immediately flush with running water for about 10-15 minutes. Seek the
advice of eye specialist.
2007 BMW 335i
In the event of skin contact and where applicable an allergic skin reaction, clean the affected areas immediately
with soap and water and then apply silicone-free skin cream. If necessary, consult a doctor.
If an adhesive product is swallowed, rinse mouth/parts of mouth thoroughly with running water. Drink 1-2
glasses of water. Do not induce vomiting. Consult a doctor.
After inhaling adhesive vapors ensure ample supply of fresh air. Stay calm. Keep air passages open. Consult a
doctor.
00 SAFETY INFORMATION FOR WORKING ON VEHICLES WITH AUTOMATIC ENGINE

START-STOP FUNCTION (MSA)
WARNING: If the engine hood/bonnet contact is pulled upwards (workshop mode),

the information "switch closed" is output. The automatic engine start stop
function is active.
An automatic engine start is possible.
Observe safety precautions when working on MSA vehicles
Before carrying out practical work on the engine, always ensure that the MSA functionality is deactivated so as
to prevent automatic engine starting while work is being carried out in the engine compartment.
MSA function is deactivated by
 Deactivate MSA by means of button (1) in passenger compartment

 Open seat belt buckle and driver's door
Fig. 69: Identifying Automatic Engine Start/Stop Button (MSA)

 Open engine bonnet/hood and ensure that engine hood/bonnet contact is not in workshop mode
 Workshop mode
A = 10 mm
 Basic setting (engine hood/bonnet open)
B = 7 mm
2007 BMW 335i
Fig. 70: Identifying Basic Setting For Engine Hood/Bonnet Basic

To make sure that the engine hood/bonnet contact is at the basic setting, if necessary press the
hood/bonnet contact up to the limit position before starting work and slowly release.
When working with diagnosis tools
 Observe instructions in diagnosis tool
41 00... SEPARATING CUT DETERMINATION WITH A TEMPLATE
A template may be used for the exact position determination for the separating cut.
The template is made from the reinforcement plate and can be reused.
Carry over schematic diagram at the separation cut C-pillar to the relevant vehicle type.
Remove stud bolts (1).
Set bore holes Ø 4 mm at the positions of the removed stud bolts.
If applicable, place additional bore holes in the area of the edges.

2007 BMW 335i
Fig. 71: Identifying Stud Bolts

Insert the template (1) into the new part (in direction of arrow) until it is flush (without gap).
Carry over the positions of the holes (2) to the new part.
Remove reinforcement plate again.
Fig. 72: Inserting Template Into New Part

Connect marks (positions of holes) to the separating cut line (1).
Carry out the separating cut.
Tear and separate the separating cut on the vehicle according to the new part.
2007 BMW 335i
Fig. 73: Identifying Connecting Position Of Holes And Separating Cut Line
41 00... SETTING BLIND RIVET NUTS AND BOLTS
 Studs welded as standard are always replaced by blind rivet bolts.

 Blind rivet nuts and studs must have a special coating for anticorrosion purposes.
 It will no longer be possible to set a blind rivet nut if the drilled hole is too big. In this event, set a clip
nut. This nut tightens itself automatically when screwed to the component.
 Insert blind rivet nuts or bolts and TIGHTEN DOWN WITH RIVET TOOL .
 Seal blind rivet nuts and blind rivet bolts with SEALANT (risk of corrosion).
41 00... SPOT-WELD BONDING STEEL COMPONENTS
Safety regulations: see SAFETY AT WORK and INFORMATION ON HAZARDS.
Handling electrical/electronic equipment, airbags and restraint systems: see

HANDLING AIRBAGS AND RESTRAINT SYSTEMS and HANDLING
ELECTRICAL AND ELECTRONIC EQUIPMENT.
Welding of steel parts: see WELDING AND SOLDERING STEEL PARTS.
 The spot-weld bonding process is used starting from the E65 to increase vehicle rigidity. In partial
bodywork areas, a 1-component adhesive is applied to the spot flanges and this is followed by resistance
pressure spot welding. The adhesive is hardened only after the paint drying process (at approx. 180°C).
 In the case of repairs, adhesive is not applied to the spot flanges. The number of welding spots is doubled
as a substitute for the omitted adhesive.
2007 BMW 335i
 The following processes are used as a substitute for spot-weld bonding:

welding).
 Adhesive is not applied between the spot flanges on new parts in the case of 2- or multi-sheet
joints. Areas which cannot be reached by the spot-welding tongs can be joined by MAG spot
welding. The number of welding spots is doubled as a substitute for the omitted adhesive.
Exceptions (e.g. E65) are described in the relevant repair instructions. Apply welding spots to
existing welding spots on new part. This is necessary because the adhesive between the spot flanges
of the new part acts as an insulator.
CAUTION: Extract smoke and fumes during welding work.


41 00... STAMPING VEHICLE IDENTIFICATION NUMBER
NOTE: If the stamped vehicle identification number is removed during repair work, it
must be stamped in again.
Read and comply with VEHICLE IDENTIFICATION NUMBER, GENERAL.
 Remove FRONT RIGHT SPRING STRUT

 Remove rubber base from guide plate 41 1 141
The set of special tools 41 1 140 for stamping the vehicle identification number consists of:
Guide plate 41 1 141
Counter-support plate 41 1 142

2007 BMW 335i
Fig. 74: Identifying Guide Plate And Counter-Support Plate

Position counter-support plate 41 1 142 at bottom on spring strut dome.
Position guide plate 41 1 141 at top on spring strut dome and tighten screws (1) by hand.
Fig. 75: Identifying Counter-Support Plate And Guide Plate With Screws
Tighten screw (1) until counter support 41 1 142 rests on spring strut dome.
Fig. 76: Identifying Screw And Counter Support 41 1 142

Tighten down screws (1).

2007 BMW 335i
Fig. 77: Identifying Counter-Support Plate And Guide Plate With Screws

Insert punch numbers 41 0 000 (1) individually into guide plate (2) and stamp vehicle identification number.
Fig. 78: Inserting Punch Number 41 0 000 Into Guide Plate

NOTE: In the event of component or body replacement by the workshops/garages,

clearly delimit the vehicle identification number at front and rear by stamping a
"+" in place of the BMW emblem.
Note national regulations.
41 00... STRAIGHTENING ALUMINUM COMPONENTS IN STRUCTURE
Reshaping or heating extruded sections and cast parts is not permitted!

2007 BMW 335i
Failure to comply with this requirement would have the following results:
In the case of reshaping, weld seams (E52) or glued connections (E60, E61, E63, E64) tear in the surrounding
area.
In the case of reshaping, the material loses up to 40 % of its original strength.
In the case of heating, the material loses up to 40 % of its original strength.
The adhesive is destroyed at temperatures =120°C (E60, E61, E63, E64).
Extruded sections and cast parts which show visible or measurable signs of deformation must be replaced.
Perform the check for deformation with the aid of the straightening system.
For optical testing, strip adjoining components in cases of doubt.
Extruded sections are used in the E52 as engine supports, door pillars, side members, etc.
Extruded sections are used in the E60, E61, E63, E64 as engine supports.
Cast parts are used in the E60, E61, E63, E64, E70, E71 as spring supports.
 Reshaping of extruded sections and cast parts may only be used to achieve optimum joining of connecting
faces (e.g. when bulkhead is damaged). Reshaped parts must be replaced.
 Repairs which affect the mounting points of mechanical assemblies and chassis components must be
carried out on the straightening bench. Use the vehicle-specific straightening attachment set or vehicle-
specific data sheet.
Straightening attachment supports and data sheets are also available for the top section, e.g.: door pillars,
diagram.
 Exceptions on the E60, E61, E63, E64:
Carrier support and bulkhead may be straightened if they do not have any cracks, sharp-edged damage or
holes. After repair work, check parts again for cracks.
Examine adjoining adhesive flanges for peeling off. If necessary, seal and preserve with SEALING
COMPOUND.
Observe the frame alignment control dimensions for the carrier support.
Any repairs to the bulkhead if cracked outside the approved repair scopes are only permitted after
consultation with and approval by BMW. Should you have any questions, please contact the country-
2007 BMW 335i
specific Hotline.
41 00... STRAIGHTENING ALUMINUM COMPONENTS ON THE OUTER SKIN
 Use only those tools specially intended for aluminum repairs.

 Do not use any tools that have already been used for steel repairs (contact corrosion).
 Do not use any sharp-edged tools (notch effect).
 "Cold" straightening: Press dents out from their center and smooth in an outwards direction with gentle
taps.
 "Hot" straightening: Heat dents in their central point only with a gas flame or hot air blower. Then quench
the material with a wet cloth. Heating can only be detected by warpage of the material. The color of the
paint does not change.
 In the case of damaged areas which are only accessible from one side, stud welding can be used. The
aluminum stud welded on in the center of the damaged area is beaten out with a hammer until the dent is
eliminated. The stud is then ground off.
 Avoid notching and cracking.
41 00... STRAIGHTENING STEEL COMPONENTS IN THE STRUCTURE
points.
 Bearing body components such as e.g. engine supports, door pillars, side members etc. with deformations
which can no longer be returned to their original shape by "cold straightening" must be replaced.
The body must be anchored as follows for reshaping
If using vehicle-specific/universal straightening attachment sets (Carbench/Celette/Car-O-Liner), it is necessary

to secure the body additionally with 4 retaining clips to the spot flange of the entrance or to the 4 jacking
points. The spot flange (if available) is to be preferred.
2007 BMW 335i
If using universal electronic or mechanical straightening systems (Car-O-liner/Celette), it is necessary to secure

the body with 4 retaining clips to the spot flange of the entrance or to the 4 jacking points. The spot flange (if
available) is to be preferred. In addition anchor at least 2 points with the securing set.
Failure to comply with these instructions will result in damage to the body during reshaping in non-damaged
areas. Vehicle-specific straightening attachments and universal mounts may be damaged.
the vehicle.
diagram.
41 00... STRAIGHTENING STEEL PARTS
taps.
 Avoid cracking.

2007 BMW 335i
01.07.2003!
 For safety vehicles, follow the special notes and information in the repair instructions.
3.0 Straightening structure
the vehicle.
diagram.
 Bearing body components such as e.g. engine carriers, door pillars, frame side members etc. with
deformations which can no longer be returned to their original shape by "cold straightening" must be
replaced.
points.
The body must be anchored as follows for reshaping
If using vehicle-specific/universal straightening attachment sets (Carbench/Celette), it is necessary to secure the

body additionally with 4 retaining clips to the spot flange of entrance or to the 4 jacking points. The spot flange
(if available) is to be preferred.
If using universal electronic or mechanical straightening systems (Car-O-liner/Celette), it is necessary to

secure the body with 4 retaining clips to the spot flange of entrance or to the 4 jacking points. The spot
flange (if available) is to be preferred. In addition anchor at least 2 points with the securing set.
Failure to comply with these instructions will result in damage to the body during reshaping in non-
damaged areas. Vehicle-specific straightening attachments and universal mounts may be damaged.
41 00... STRAIGHTENING STEEL PARTS ON OUTER SKIN

2007 BMW 335i
taps.
 Avoid cracking.
41 00... WELDING AND SOLDERING STEEL PARTS
 Safety regulations: see SAFETY AT WORK and INFORMATION ON

HAZARDS.
 Handling electrical/electronic equipment, airbags and restraint systems:
see HANDLING AIRBAGS AND RESTRAINT SYSTEMS and HANDLING
ELECTRICAL AND ELECTRONIC EQUIPMENT.
A. Welding steel parts
1. General information
 The following procedures are used for repairs:

welding).
 Take the number and location of weld spots and MAG weld seams from the separated part. Replace areas
inaccessible to spot-welding tongs with MAG plug/spot welds at the same distance. Diameter of bores for
plug/spot welds 8 mm.
 In the case of emissions extraction, observe a minimum distance of 30 cm for MAG welding during the
welding process. Otherwise the inert gas would be drawn off.
 Follow the equipment manufacturer's instructions for use.
2007 BMW 335i
2. Work materials
 MAG welding:
 Steel welding apparatus (see WORKSHOP EQUIPMENT).
 Steel welding wire - G3SI1 (SG2) or alternatively G4SI1 (SG3)
 Welding mask
 Gas bottle containing inert gas (82 % argon, 18 % CO )

2
 Resistance pressure spot welding:
 Spot-welding apparatus (see WORKSHOP EQUIPMENT).
 Protective goggles
3. Preparations for MAG and spot-welding
 Remove the paint coating in an area of approx. 30 mm around the weld seam or spot.
 The zinc coating underneath must be removed during the MAG welding operation.
 It is not necessary to remove the zinc coating underneath during spot-welding.
 Remove the paint coating on the reverse side of the weld seam or spot.
 Contaminants will otherwise enter the weld pool via the root of the weld seam.
 An insufficient electron flow prevents an optimum spot-weld joint.
 Coat all metal overlaps and weld spot flanges with welding primer.
 To determine the optimum electrode contact force for spot-welding, carry out spot-weld shear tests on
sample metal sheets.
 In order to keep the electron flow short during MAG welding on the body, you must if possible attach the
ground terminal directly to the component to be welded.
4. Welding
 During MAG welding, the weld gap must be kept as small as possible. The larger the weld gap, the lower
will be the strength of the joint.
 During spot-welding, the metal flanges to be joined must be placed as close together as possible without
gaps.
The larger the gap, the lower will be the strength of the joint.
Minimum gap between welding spots 25 mm.
5. Subsequent treatment of weld joints
 When grinding a weld seam, do not grind thin the base material next to the seam.
 After joining, clean all weld seams and spots with a stainless steel wire brush.
 Remove burnt paint with a stainless steel wire brush.
 All weld joints sealed off with body sealing compound in original state must be primed and sealed off
again thoroughly after repairing. Replace damaged or removed antinoise compounds.
2007 BMW 335i
B. Soldering steel parts
1. General information
 The following procedures are used for repairs:

 Gas brazing
 Tinning
 The MIG soldering procedure is not used in repairs for strength reasons. MIG soldered/brazed seams
used in series production are replaced in repairs by MAG weld seams.
 Areas brazed in vehicle production are joined during repairs with the same procedure.
 It is possible when straightening steel parts to correct irregularities smaller than 2 mm with filler.
If in exceptional cases the irregularities are in excess of 2 mm, these areas must be tinned.
Only visible areas of the outer skin and on the support carrier must be tinned.
All areas which have covers on the vehicle are not to be tinned.
01.07.2003!
2. Work materials
 Gas brazing:
 Tube pack and torch (gas torch)
 Brazing solder
 Gas bottles (oxygen and acetylene)
 Welding goggles
 Tinning:
 Tube pack and torch (torch for tinning)
 Tinning paste
 Tin (refer to "BMW Electronic Parts Catalogue" ETK).
 Gas bottle (acetylene)
 Protective goggles
3. Preparations for brazing/tinning
 Heat brazed joints to be opened with an autogenous flame. Lift off remaining metal and remove
remaining brazing solder with a wire brush.
 Remove the paint and zinc coating in an area of approx. 30 mm around the seam to be soldered.
 Remove the paint and zinc coating in the tin-plating area and approx. 30 mm beyond.
2007 BMW 335i
4. Brazing/tinning
 Execute brazed seam without overheating the solder and with low heat dissipation. If necessary, use heat
protecting paste.
5. Subsequent treatment of brazed joints
 Remove burnt residual zinc completely. Straighten, grind and tin visible connection points.
 Remove burnt paint with a stainless steel wire brush.
99 00..TOUCHING UP PAINTWORK DAMAGE
These notes apply to paintwork damage on the body aperture that occurred when detaching bonded window
glass.
To ensure long-term corrosion protection, it is absolutely essential to touch up damage to paintwork!
The "BMW Color System" painting handbook forms the basis of these repair instructions and must be observed
without fail.
Ground down damage to paintwork on body aperture and touch up with BMW multibase filler.
Grind larger areas or damage down to the bare sheet metal and coat with BMW multibase filler (layer thickness
30 to 40 µm).
Hardening time:
 With infrared, at least 10 minutes

 Without infrared for at least 60 °C, at least 30 minutes
 Without infrared for at least 20 °C, at least 24 hours
If a complete build-up of paint is required in the visible area:
 Tape off primed adhesive flange before applying top coat
IMPORTANT: Observe hardening time of BMW multibase filler otherwise a perfect bond
cannot be guaranteed!
41 00... USE OF MATERIALS IN OUTER SKIN
The following illustration is a schematic representation of all the body variants.
Apply this illustration to the relevant vehicle.

2007 BMW 335i
Fig. 79: Identifying Body Components

All components not listed in the table below are composed of established sheet steel qualities.
COMPONENTS REFERENCE CHART

Component Vehicle Material
(1) Side panel, front E52 (Z8) Aluminum
E60, E61 Aluminum
E63, E64 Plastic (thermoplastic)
E65, E66: Aluminum
E70, E71, E92, E93 Plastic (thermoplastic)
E89 (Z4) Aluminum
(2) Front door E36/C (M3) Aluminum or steel
E36/2 (M3) Aluminum or steel
E52 (Z8) Aluminum
E63, E64 Aluminum
(4) Side panel, rear E52 (Z8) Aluminum
(5) Engine compartment lid E38 (750i) Aluminum or steel
(5) Engine compartment lid E46/C (M3) Aluminum
E46/2 (M3) Aluminum
E52 (Z8) Aluminum
E60, E61, E63, E64 Aluminum
E65, E66, E70, E71 Aluminum
E85 (Z4) Aluminum
E92 (M3) Aluminum
E89 (Z4) Aluminum
(6) Hardtop/roof E36/C Aluminum
E36/7 (Z3) Plastic (glass fibre/epoxy resin)
E46/C Aluminum
E46/2 (M3 CSL) Plastic (CFK)
2007 BMW 335i
E52 (Z8) Plastic (PU)

E85 (Z4) Plastic (SMC)
E63 (M6) Plastic (CFK)
E89 (Z4) Aluminum
(7) Soft top compartment lid E46/C Magnesium
E64 Plastic (SMC)
(8) Rear lid E46/2 (M3 CSL) Plastic (SMC)
E52 (Z8) Aluminum
E63, E64 Plastic (SMC)
41 00... VEHICLE IDENTIFICATION NUMBER, GENERAL
In the event of repair 2 procedures are used, depending on the vehicle.
1. General notes for stamped vehicle identification numbers
The vehicle identification number is stamped with a special tool. There are different special tool numbers and
stamping procedures for the various vehicles.
In repair work, the vehicle identification number is always stamped into a replacement vehicle identification
number surface. The replacement surface is usually situated under the original VIN surface.
In the event of component or body replacement by the BMW garages/workshops, clearly delimit the vehicle
identification number at front and rear by stamping a + in place of the BMW badge.
If a VIN is stamped into the replacement surface in addition to the original VIN (e.g. if the original VIN has
been tampered with), the following applies: The original VIN must be crossed out. To do so, stamp the letter I
from the punch digits lengthways through the original VIN.
IMPORTANT: Do not use an angle grinder in conjunction with a cutting disk!
The protective film used as standard is omitted after the VIN has been manually stamped in. Paint area in
accordance with BMW Painting Handbook. Ensure that layer thicknesses are small.
Observe national/country-specific regulations.
2. General notes for embossed vehicle identification numbers
This procedure is used on all newly launching model series from model year 09/2008 (exception X1).
For the repair new parts with an embossed vehicle identification number can as a rule be ordered from the
BMW Parts Department. If this is not possible, observe country-specific regulations.
2007 BMW 335i
If a VIN is embossed into the replacement surface in addition to the original VIN (e.g. if the original VIN has
been tampered with), the following applies: The vehicle-specific repair instructions describe the procedure.
The protective film used as standard is omitted after the VIN has been embossed. Paint area in accordance with
BMW Painting Handbook. Ensure that layer thicknesses are small.
Observe national/country-specific regulations.
4100... WORKING WITH 2-COMPONENT PU CAVITY FOAM
Sourcing reference for cavity foam, refer to BMW Parts Service.
Properties of cavity foam:
 2-component PU foam, solvent-free.

 Excellent flow capacity, enabling complete sealing of cavities.
 Good strength, preventing slipping in cavities.
 Low water absorption, preventing corrosion.
 Ideal for use as insulating and sealing compound
Information on dangers/hazards
 Avoid eye and skin contact.
Wear protective goggles, solvent-resistant protective gloves and protective clothing.
 Do not inhale.
Apply in well ventilated rooms only.
WARNING: Application time after mixing: within 8 minutes!
 Completely empty open can after use.

 Remaining amounts which are not used can cause the can to explode on account of a chemical reaction
(buildup of heat)!
Alternatively, cool the can containing the non-removed remaining amount for several hours in cold water.

 Keep heat and ignition sources well away.
 Read the manufacturer's information on hazards/dangers (printed on the can) prior to application.
Application instructions
2007 BMW 335i
 Use by date on can.
Do not use the spray can after the Use by date on the can has expired. After the Use by date the properties
of the cavity foam will no longer meet the requirements of the BMW Group.
 Cavity sealing of repair area possible after an air drying time of 1 hour.
 Backing surface must be
clean and free from
dust,
grease,
oil and stripping agent.
 Application temperature at least 15°C. Optimally 20°C.

 Remove fresh, non-hardened PU foam with adhesive cleaner 208.
Sourcing reference: BMW Parts Service.
Hardened PU foam can only be removed by mechanical means (machine).
 Excess, hardened PU foam can be disposed of as residual waste.
Cans which are not entirely empty and unused whose Use by date has expired are classed as hazardous
waste.
 Observe the manufacturer's application instructions (printed on the can).

IMPORTANT: Foam expands many times over as it sets (change in volume).
 Setting takes approx. 30 minutes. Mechanical processing (e.g. drilling, cutting, etc.) is then possible.
41 05 504 REPAIR SOLUTION FOR STRAIGHT SHANK/HEXAGON RIVET NUT

IMPORTANT: To prevent the material from tapering, do not drill out the rivet head.
1. Carefully spot-drill rivet head with a larger drill bit/countersink

2007 BMW 335i
IMPORTANT: Avoid paintwork damage
Fig. 80: Spot-Drilling Rivet Head

2. Knock rivet head away with a chisel
Fig. 81: Removing Rivet Head With Chisel

3. Drive through rivet shank into cavity, remove if necessary

2007 BMW 335i
Fig. 82: Driving Through Rivet Shank Into Cavity

4. Clean component, eliminate paintwork damage if necessary
Fig. 83: Newly Drilled Hole In Component

5.
A. If the rivet shank can be removed:
IMPORTANT: To avoid corrosion, stop chips/debris by means of cavity sealing.
Follow Instructions On Corrosion Protection.
Preserving cavity
2007 BMW 335i

B. If the rivet shank cannot be removed:
WARNING: Risk of injury!
Observe notes on cavity foam.
IMPORTANT: To avoid corrosion and rattling noises, stop chips/debris and rivet
nut shank with cavity foam.
Remove foam remnants with isohexane (cleaning-grade petroleum

spirit).
Stop rivet shank by means of specific foaming
NOTE: Fit rivet nut as quickly as possibly, ideally before the cavity foam
hardens.
2007 BMW 335i

6.
A. Hexagon rivet nut (up to M8 thread), straight shank rivet nut:

Make sure rivet nut correctly contacts component.
Set rivet nut with hand rivet gun
NOTE: The pictured tool in is suitable up to an M8 thread

B. Hexagon rivet nut (from M10 thread):
IMPORTANT: Ensure correct screw length. The complete thread length of the rivet
nut must be used for installation.
Insert screw (tensile strength min. 10.9) with body washer into hexagon rivet nut
7. Insert hexagon rivet nut into pre-punched hexagon hole and install by turning screw
NOTE: On Installation:
Rivet nut is upset (screw very difficult to move).

2007 BMW 335i
Rivet nut is contracted (screw comparatively easy to move).
Rivet nut is pressed onto the component (screw slowly becomes difficult
to move). Procedure is finished with the fitting of the relevant component
and its tightening torque
Fig. 87: Hexagon Rivet Nut And Component

41 07 100 NOTES ON CAVITY FOAM
WARNING: Cavity foam is damaging to health and highly flammable!
Empty the can completely immediately after use. Foam material set even
in the can. There is therefore a danger of bursting as a result of foam
expansion, even when the can is partly empty.

 Wear solvent-resistant protective gloves
Recycling:
Not fully emptied and unused cans with elapsed expiry dates must be treated as special waste.
Foam which has set can be disposed of as residual waste.
IMPORTANT: Do not fill cavity completely (risk of damage).
Foam expands while it sets by several times over (volume change). Setting
2007 BMW 335i
takes approx. 30 minutes. Mechanical processing (e.g. drilling, cutting, etc.) is

then possible.
Note on mixing:
Perform activation at room temperature only.
Foam material has two components and must be activated prior to use in the can. The operations pictured on the
can must be carried out for this purpose.
Activated cavity foam can be used when the foam color is uniform.
The application time is approx. 5 minutes. The cavity foam must be introduced within this period.
Fig. 88: Cavity Foam Container

99 00... GENERAL INSTRUCTIONS ON PAINTING
General instructions and classification of paint stages are described on the BMW KSD-CD (notes-general
information on flat rate unit data, passenger car explanation for FR specifications for painting).
The marked area serves as the starting point for painting. This area may differ from the illustration for technical
painting reasons.
Touching-up areas are taken in to account.
99 00... SECTIONAL PAINTING
Follow general instructions on painting.
Rear side panel below cutting edge
Area specification applies to all paint stages.

2007 BMW 335i
Fig. 89: Rear side panel below cutting edge

Rear side panel above cutting edge
Fig. 90: Rear side panel above cutting edge

Front door above cutting edge

2007 BMW 335i
Fig. 91: Front Door above cutting edge

Rear lid, top
Fig. 92: Rear lid, top

Rear lid, bottom

2007 BMW 335i
Fig. 93: Rear lid, bottom

SUPPORT MEMBERS
41 11 023 REPLACING FRONT SECTION OF ENGINE SUPPORT TO LEFT WHEEL ARCH
Observe procedure for repair stage 3.
Read contents of Body, General .
Remove or cover those vehicle components in the repair area which are susceptible to heat or dust.
Strip down vehicle.
Place vehicle on straightening bench.
Following new body parts are required:
1. Wheel arch, front

2. Support carrier, wheel arch, outer
Following consumables are required:
Material Quantity
Adhesive K1 1
Blind rivets N1 41
Punch rivets N5 39
EMC screws 2
Cleaning agent R1 1
Cavity sealing wax remover 1
Sealant D1
2007 BMW 335i
Fig. 94: Wheel Arch Front And Support Carrier Wheel Arch Outer
Removal of front section of engine support with wheel arch:
Mark severance cut (1) in front of holder (2) and cut (holder (2) remains on vehicle).
Open welded connections in area (3).
Installation note:
Mark severance cut (1) in on new part and cut. Take off holder (2).
Apply sealant to cavity sealing (4). See (expanded) or (not expanded).
Fig. 95: Identifying Severance Cut With Sealant And Welding Areas
Mark severance cut (1) in accordance with dimension a and cut engine support.
IMPORTANT: Cut outer metal panel only.

2007 BMW 335i
Dimension a=130 mm from front edge of bush
Fig. 96: Identifying Measurement From Front Edge Of Sleeve

Open welded connections in areas (1).
Fig. 97: Identifying Weld Joint Areas (1 Of 6)


2007 BMW 335i

Installation note:
If equipment compartment partition wall (2) is damaged, cut along line (3).
Mark severance cut on new part according to severance cut on vehicle + 20 mm material extra and cut.
Bond both parts overlapping and rivet. Depending on accessibility, use punch rivets N4 and blind rivets N3.

Remove front section of engine support with wheel arch.

2007 BMW 335i

Preparation of new part:
Mark and cut the severance cut on new part as per the severance cut on the vehicle.
Prepare reinforcement plates at severance cut.
Open welded connections in areas (1) on both sides.
Detach remainder of reinforcement from engine support.

Take off holder.

2007 BMW 335i

Adjust new parts to fit with alignment bracket or universal mount and secure.
Fig. 103: Identifying Universal Mount

In area (1) set ten 6.8 mm dia. bore holes for blind rivets N1.
Installation note:
In area (2) 2 N5 punch rivets are used later.

2007 BMW 335i
Fig. 104: Identifying Rivet Areas

In areas (1) and (2) set 6.8 mm dia. bore holes for blind rivets N1:
 Area (1): 3 bore holes


In area (1) set seven 6.8 mm dia. bore holes for blind rivets N1.
Installation note:
In area (2) 1 N5 punch rivet is used later.

2007 BMW 335i

In areas (1) to (4) set 6.8 mm dia. bore holes for blind rivets N1:

 Area (3): 1 bore hole
Installation note:
After adhesive has hardened install 2 EMC screws in areas (1) and (4).
2007 BMW 335i

Set two 6.8 mm dia. holes for blind rivets N1 in area (1).
Remove all new parts and deburr holes.
Fig. 108: Identifying Open Weld Joints Area

IMPORTANT: Structure bonding!
Observe preparation of bonding surfaces.
Installation of engine support with wheel arch
Clean bonding surfaces with cleaning agent R1.
Apply adhesive K1 to bonding surfaces.
Install new parts and reinforcement plates with alignment bracket or universal mount.
Rivet new parts with blind rivets.
IMPORTANT: Three-sheet-metal combination in area (1)!
In area (1) rivet new part on both sides offset with 4 punch rivets N5.
Use 14 punch rivets N5 in area (2).

2007 BMW 335i
Fig. 109: Identifying Rivet Areas On Wheel Arch

In area (1) rivet new part with blind rivets N1.
In area of severance cut, weld new part of engine support and reinforcement plates.

NOTE: Vehicles with spring strut dome plate insert:
Different plate inserts are fitted, depending on the model.
 Version (A) riveted

 Version (B) screwed
IMPORTANT: Use only identical plate inserts on both sides of the vehicle.
2007 BMW 335i
Riveted version:
If damaged, the plate inserts must always be replaced with screwed versions on both sides of the vehicle.
Fig. 111: Identifying Rivet Spring Support Plate

Glued version:
Adhesive/contact surfaces of plate insert must be free of sealant, top coat and underbody protection.
Do not grind off primer.
Use adhesive gun 41 3 102 in conjunction with adhesive K3.
Apply K3 adhesive in areas (1). Do not apply any adhesive in area (2).
Secure plate insert with 3 screws and nuts for 2 hours at min. 20 °C.
IMPORTANT: Operational strength is only achieved after 12 hours!

2007 BMW 335i
Fig. 112: Spring Support Plate Insert Adhesive Areas And No Adhesive Area
41 11 023 STRIPPING OPERATIONS - REPLACING FRONT SECTION OF ENGINE SUPPORT

WITH LEFT WHEEL ARCH
NOTE: Owing to the different engine variants and equipment specifications, not all the
components are taken into consideration.
The following list basically represents the removal sequence.
 Disconnect battery negative lead

 Remove bumper trim
 Remove headlight
 Remove bumper carrier
 Remove front panel
 Remove radiator
 Remove A/C system condenser
 If necessary, remove intercooler
 If necessary, remove coolant expansion tank
 If necessary, remove air filter housing
 Remove hydraulic steering cooling coil
 Remove cowl panel cover
 Remove left wheel arch cover (front section)
 Remove left wheel arch cover (rear section)
 Remove left side panel
 Remove engine
 Remove and install complete front axle
 Remove tandem brake master cylinder
 Remove brake booster
2007 BMW 335i
 Release left wiring harness
41 11 028 REPLACING LEFT ENGINE CARRIER (PARTIAL REPLACEMENT BEFORE FRONT

AXLE)
Observe procedure for repair stage 3.
Strip down vehicle.
 (1) Partial section, engine support

 (2) Holder for diagonal strut
 (3) Repair element (not shown)
 (4) Screw (not shown)
CONSUMABLES REQUIRED - LEFT ENGINE SUPPORT REPLACEMENT

Material Quantity
Adhesive K1 1
Blind rivets N1 2
Blind rivets N2 10
Cleaning agent R1 1
Sealant D1
Fig. 113: Identifying Partial Section Engine Carrier And Bracket Diagonal Strut
2007 BMW 335i
Removing carrier support
Mark severance cut (1) in accordance with measurement a and cut.
Measurement a=125 mm
IMPORTANT: Clean engine support - measured min. 50 mm from cutting edge - thoroughly
with cavity sealing wax remover.
Fig. 114: Marking Severance Cut

Take off holder.

2007 BMW 335i
Fig. 115: Identifying Welding Areas

Mark severance cut (1) in accordance with vehicle and cut.
Fig. 116: Identifying Severance Cut

Open welded connections on holder (1) by grinding with a belt grinder from inside.
NOTE:  The inside surfaces of the engine support must be smooth. If necessary,
surface-grind existing raised areas.
 Belt grinder, see Aftersales Assistance Portal (ASAP)
Service/Technology - Workshop Equipment - Start BMW
Or at: www.bmwbroup-wep.com
Fig. 117: Identifying Holder

2007 BMW 335i
Adjust new part to fit with alignment bracket or universal mount.
Drill hole (1) at side.
Take hole position from repair element.
Hole diameter 12 mm
Remove new parts.
Fig. 118: Identifying Drilling Hole

Installing engine support
NOTE: Schematic diagram without alignment bracket or universal mount.
IMPORTANT: Do not grind/sand new parts in area of bonding surfaces.
Insert screw (2) in repair element (1).
Clean all bonding surfaces with cleaning agent R1.
Apply adhesive to repair element.

2007 BMW 335i
Fig. 119: Identifying Repair Element And Screw

Carefully slide repair element (1) into body engine support.
Make sure there is sufficient adhesive on the bonding surfaces.
Fig. 120: Identifying Repair Element

Push new part onto repair element and secure with alignment bracket or universal mount.
Expand repair element with screw until it rests on engine support and adhesive can be seen to emerge.
NOTE: Do not tighten bolt too tightly!

2007 BMW 335i
Make sure the bonding surfaces are correctly aligned, especially on the engine end.
Fig. 121: Identifying Bolt

In area (1) install 6 blind rivets N2.

In area (1) install 2 blind rivets N2.

2007 BMW 335i

Adjust holder (1) with diagonal strut to fit.
In areas (2) and (3) set four 6.8 mm dia. holes.
Remove holder (1) and deburr holes.
Clean bonding surfaces (2) and (3) with cleaning agent R1.
Rivet bracket in area (2) with blind rivets N1.
In area (3) use blind rivets N2.
NOTE: Remove screw after adhesive has hardened.
Seal separation point and hole with sealant.

2007 BMW 335i
Fig. 124: Adjusting Holder

41 11 028 STRIPPING OPERATIONS - REPLACING LEFT ENGINE SUPPORT (PARTIAL

REPLACEMENT BEFORE FRONT AXLE)
 Clamp off battery lead from negative terminal

 Remove and install intake filter housing
 Remove and install left wheel arch cover (front section)
 Remove and install A/C system condenser
 Remove and install hydraulic steering cooling coil
 If necessary, remove and install intercooler
 Partially release left wiring harness
41 11 043 REPLACING FRONT SECTION OF LEFT ENGINE SUPPORT
Use only approved Spot-Welding Apparatus for repairs.

2007 BMW 335i
1. Engine carrier, front

2. Bracket for diagonal strut (not illustrated)
Fig. 125: Engine Carrier Front

Mark severance cut (1) in accordance with measurement a and cut engine carrier.
IMPORTANT: Cut outer metal sheet only.
Measurement a=130 mm from front edge of sleeve
Installation:
Weld in Reinforcing Panels at all severance cuts.
Fig. 126: Severance Cut Mark And Measurement Area

Open weld joints in areas (1).

2007 BMW 335i
Fig. 127: Open Weld Joints Areas


Mark new part in accordance with severance cut on car and cut.
Open weld joints in areas (1) on both sides.
Open weld joints in area (2).
Detach remainder of reinforcement from engine carrier.

2007 BMW 335i

Take off holder.

Installation:
Adjust new part to fit with straightening attachment or universal mount.

2007 BMW 335i
Fig. 131: Universal Mount

Weld new part in area (1) with additional MAG weld seams.
Fig. 132: New Part MAG Weld Area

Installation:
Position bracket for diagonal strut (2) and weld in area (1).
2007 BMW 335i
Fig. 133: Diagonal Strut Bracket And Weld Area

41 11 141 REPLACING COVER FOR LEFT OR RIGHT FRAME SIDE MEMBER (PARTIAL
REPLACEMENT BETWEEN A- AND B-PILLARS) (COUPE)
Read contents of BODY, GENERAL .
1. B-pillar with entrance
Fig. 134: B-Pillar With Entrance

2007 BMW 335i
Fig. 135: Severance Cut Marks, Distances And Weld Joint Areas
Mark severance cuts (1) in accordance with specified measurements and cut.
Distance a = approx. 225 mm behind bore dia. 20 mm.
Distance b = approx. 250 mm before bore dia. 25 mm.
Installation:
Weld reinforcement plates at all severance cuts (1).
41 11 141 REPLACING COVER FOR LEFT OR RIGHT FRAME SIDE MEMBER (PARTIAL
REPLACEMENT BETWEEN A- AND B-PILLARS) (CONVERTIBLE)
1. B-pillar with entrance

2. Shaped part, entrance (not shown)
2007 BMW 335i
Fig. 136: Identifying Side Frame, Outer

Mark severance cuts (1) in accordance with specified measurements and cut.
Measurement a = approx. 85 mm behind A-pillar
Measurement b = approx. 35 mm before side panel at rear
Installation:
Weld reinforcement plates at all severance cuts (1).
Apply window glass adhesive to cavity acoustic baffle (3).
Fig. 137: Identifying Side Frame And Shaped Part

41 11 516 REPLACING FRONT LEFT OR RIGHT SUPPORT CARRIER (PARTIAL

REPLACEMENT, FRONT SIDE PANEL REMOVED)
2007 BMW 335i
STRIP DOWN vehicle.
NOTE: Observe procedure for REPAIR STAGE 2.
Carry over schematic diagram to the relevant vehicle type.
 Support carrier, wheel arch, outer
Material Quantity
Adhesive K5a 1
Blind rivets N1 2
Punch rivets N3 6
Punch rivets N5 12
Cleaning agent R1 1
Sealant D1
Fig. 138: Outer Wheel Arch Support Carrier

Removing carrier support
IMPORTANT: Cut outer metal panel only.
Mark severance cut (1) through 20 mm dia. hole and cut carrier support.
2007 BMW 335i
Fig. 139: Identifying Severance Cut And Welding Areas

Mark severance cut in accordance with measurement a and cut support carrier.
Measurement a=240 mm from edge of rectangular hole.
Fig. 140: Weld Joint Areas And Measurement

Remove carrier support section.

2007 BMW 335i

Make severance cut on new part in accordance with severance cut on vehicle.
Adjust new parts with add-on parts to fit and secure.
Set two 6.8 mm dia. bore holes for blind rivets N1 in area (1).
Fig. 142: Identifying Area For Bore Holes

For the severance cut, create a reinforcement plate from the trim of the new part.
In area of reinforcement plate (1) set six 4.3 mm dia. bore holes for blind rivets N3.
Remove new part again and deburr bore holes.

2007 BMW 335i
Fig. 143: Identifying Reinforcement Plate Rivet Areas

Installing carrier support
Clean all bonding surfaces (1) on vehicle and on new part with cleaning agent R1.
Apply adhesive K5a to bonding surfaces.
Fig. 144: Identifying Bonding Surfaces Of Vehicle

Install new part with add-on parts and rivet.
IMPORTANT: Three-sheet-metal combination in area (1)!
In area (2) rivet new part with 2 punch rivets N5.

2007 BMW 335i
In area of reinforcement plate (4) use 6 blind rivets N3.
Fig. 145: Identifying Reinforcement Rivet Areas

In area (1) rivet new part with 2 blind rivets N1.
Fig. 146: Identifying Blind Rivet Area

41 11 516 STRIPPING OPERATIONS - REPLACING LEFT CARRIER SUPPORT

2007 BMW 335i
 Remove support for bumper trim
 Remove radiator
 If necessary, remove intercooler
 If necessary, remove intake silencer housing
 Partially release left wiring harness
41 11 734 REPLACING COMPLETE REAR TENSION STRUT MOUNTING
 (1) Bracket, tension strut, rear
Fig. 147: Identifying Bracket, Tension Strut, Rear

Open weld joints in areas (2) on both sides of rear axle carrier (3).
Installation information:
2007 BMW 335i
To adjust new part to fit, screw down tension strut.
If vehicle is on straightening bench, adjust new part to fit with straightening attachment or universal mount.
Fig. 148: Identifying Weld Joint Areas And Rear Axle Carrier
41 11 915 REPLACING INNER LEFT OR RIGHT FRAME SIDE MEMBER COVER PARTIAL
REPLACEMENT
Spot-weld bonding is used on this vehicle. Observe specific procedure.
Use only approved spot-welding apparatus for repairs!
 (1) Inner side frame
Fig. 149: Identifying Inner Side Frame

2007 BMW 335i
Fig. 150: Identifying Inner Side Frame Dimension

Remove cavity bulkhead (1).
Mark severance cuts in accordance with specified measurements and cut.
Measurement a = approx. 30 mm after frame side member cover severance cut.
Measurement b = approx. 30 mm before frame side member cover severance cut.
Open adhesive bonds in areas (3).
Installation:
Replace adhesive in areas (3) with MAG weld seams from underside of vehicle.
Length of weld seams 20 mm with 15 mm distance.
Mark new part in accordance with severance cuts on vehicle and cut.
Maintain a distance of 3 mm at severance cuts.
Adjust new part to fit and weld severance cuts.
Installation:
Grind weld seam (1) in area of reinforcement plate (2).
Make 40 mm wide reinforcement plate (2) and adjust to fit.
Weld reinforcement plate (2) with 20 mm long MAG weld seams at distance of 15 mm on both sides.
2007 BMW 335i
Repeat procedure at 2nd severance cut.
Fig. 151: Identifying Weld Seam And Reinforcement Plate

LUGGAGE COMPARTMENT FLOOR

41 12 651 REMOVAL REQUIREMENTS - REPLACING THE LEFT LUGGAGE COMPARTMENT
FLOOR (TAIL PANEL OR SIDE WALL REMOVED)

 Remove exhaust system
 Remove heat shield
 Remove luggage compartment floor storage tub.
 Remove rear left wheel well cover
 Remove left luggage compartment wheel arch trim
 Remove audio amplifier
 Partially detach wire harness place to one side and fasten
 Partially release/remove sound insulation
41 12 651 REPLACING LUGGAGE COMPARTMENT FLOOR, LEFT SECTION (TAIL PANEL OR

SIDE WALL REMOVED) (COUPE)
Read general service information under Body, General.
Strip down vehicle.

2007 BMW 335i
NOTE: Observe new procedure for bonding and riveting (repair stage 2).
 (1) Luggage compartment floor, left

 (2) Left tensioning strap C-pillar
CONSUMABLES REQUIRED - LUGGAGE COMPARTMENT FLOOR (LEFT SECTION)

Material Quantity
Adhesive K5a 1
Blind rivets N3 20
EMC screws 8
Cleaning agent R1 1
Sealant D1
Fig. 152: Identifying Left Luggage Compartment Floor And Left Tensioning Strap C-Pillar
Removal of luggage compartment floor

2007 BMW 335i

With removed tail panel:
Mark severance cut (1) and disconnect tensioning strap (2).
Installation:
Mark severance cut on new part C-pillar reinforcement acc. to vehicle + 25 mm material extra and disconnect.
Bond tensioning strap in area of the overlap with 3 blind rivets N3 and rivet.
Fig. 154: Identifying Severance Cut And Tensioning Strap

For removed side wall:

2007 BMW 335i
Release welded connection in area (1) and remove tensioning strap (2).
Installation:
Bond tensioning strap in area (1) with 3 blind rivets N3 and rivet.
Fig. 155: Identifying Welded Connection Area And Tensioning Strap

Mark severance cut (2) next to reinforcement (3) and disconnect.
Fig. 156: Identifying Welding Areas, Severance Cut And Reinforcement


2007 BMW 335i
Remove the trunk floor.
NOTE: Tail panel and side wall hidden for better overview.
Fig. 157: Identifying Welded Connections Area

New part preparation
On vehicle clean the connection face for bonding with cavity sealing wax remover.
Adjust and secure tensioning strap (2).
Set three 4.2 mm dia. bore holes for blind rivets N3 in area (1).

2007 BMW 335i
For removed tail panel:
Mark severance cut on tensioning strap new part (2) in accordance with severance cut on vehicle + 25 mm extra
material and cut.
Set three 4.2 mm dia. bore holes for blind rivets N3 in area of overlap.

Mark severance cut on new part luggage compartment floor according to severance cut on vehicle + 15 mm
material extra and cut.
Adjust new part in combination with tail panel and side wall to fit and secure.
Set 5 4.2 mm dia. bore holes for blind rivets N3 in area (1).
2007 BMW 335i

Set four 4.2 mm dia. bore holes for blind rivets N3 in area (2).

Installation of luggage compartment floor
Clean all bonding surfaces on new part and on vehicle with cleaning agent R1.
2007 BMW 335i
Apply adhesive to all bonding and riveting surfaces.
Install new part and rivet with blind rivets.
When installing the new part, make sure that all bonding surfaces have sufficient adhesive.
In area (1) secure luggage compartment floor until adhesive has hardened at side member.
Do not use rivets.
Fig. 162: Identifying Welding Areas On Luggage Compartment Floor

For removed tail panel:
Rivet tensioning strap (2) with blind rivets.
After adhesive has hardened in area of overlap (1) install one EMC screw.
2007 BMW 335i

Rivet tensioning strap (2) with blind rivets.
After adhesive has hardened in area (1) install one EMC screw.

After adhesive has hardened in areas (1) install 2 EMC screws.

2007 BMW 335i
Fig. 165: Identifying Areas For EMC Screws (1 Of 2)

After hardening of the adhesive, install 4 EMC screws in the areas (1).

41 12 651 REPLACING LUGGAGE COMPARTMENT FLOOR, LEFT SECTION (TAIL PANEL OR

SIDE WALL REMOVED) (CONVERTIBLE)
Read general service information under Body, General.
Strip down vehicle.
NOTE: Observe new procedure for bonding and riveting (repair stage 2).
 (1) Luggage compartment floor, left section

2007 BMW 335i
CONSUMABLES REQUIRED - LUGGAGE COMPARTMENT FLOOR (LEFT SECTION)

Material Quantity
Adhesive K5a 1
Blind rivets N3 13
EMC screws 6
Cleaning agent R1 1
Sealant D1


2007 BMW 335i

Mark severance cut (2) next to reinforcement (3) and disconnect.
Fig. 169: Identifying Welding Areas, Severance Cut And Reinforcement

Remove the luggage compartment floor.

2007 BMW 335i
NOTE: Tail panel and side wall have been hidden for clarity.

Mark severance cut on new part luggage compartment floor acc. to vehicle + 15 mm material extra and
disconnect.
Adjust new part in combination with tail panel and side wall to fit and secure.

2007 BMW 335i
On vehicle clean the connection face for bonding with cavity sealing wax remover.
Fig. 172: Identifying Blind Rivets Area

Clean all bonding surfaces on new part and on vehicle with cleaning agent R1.
Apply adhesive K5a on all bonding and riveting surfaces.
Install new part and rivet with blind rivets N3.
When installing the new part, make sure that all bonding surfaces have sufficient adhesive.
In area (1) secure luggage compartment floor until adhesive has hardened at side member.
2007 BMW 335i

After hardening of the adhesive in the areas (1) install two EMC screw.

After hardening of the adhesive, install 4 EMC screws in the areas (1).
2007 BMW 335i

51 71... REMOVING AND INSTALLING/REPLACING MULTIFUNCTION PAN
See REMOVING AND INSTALLING/REPLACING MULTIFUNCTION PAN .
41 12 535 REPLACING COMPLETE REAR LUGGAGE COMPARTMENT FLOOR (TAIL PANEL

REMOVED)
STRIP DOWN vehicle.
Spot-weld bonding is used on this vehicle. Observe specific Procedure .
Use only approved SPOT-WELDING APPARATUS for repairs.
Follow procedure for REPAIR STAGE 3
1. Luggage compartment floor, left

2. Frame side member, left
3. Frame side member, top left
4. Frame, luggage compartment floor
5. Frame side member, top right
6. Frame side member, right
2007 BMW 335i
7. Luggage compartment floor, right
Fig. 176: New Rear Luggage Compartment Body Components

Carry over the work step shown symmetrically to the other side of the vehicle.
Mark severance cuts (1) at edge of 20 mm dia. bore.
Cut frame side member (2).
Installation:
Weld in Reinforcement Plates at severance cuts.
Fig. 177: Cut Frame Side Member

Installation:
2007 BMW 335i
Weld new component in areas (2) additionally.
Fig. 178: New Components Installation And Open Weld Joints Areas
Saloon and Coupe only:

Touring only:
Open weld joints in areas (1) and (2).

2007 BMW 335i

Installation:
Weld new component in area (2) additionally.
Adjust new parts to fit with straightening attachment or universal mount.
Before welding in, also adjust tail panel, rear lid and rear lights to fit.
Fig. 181: New Component Installation And Open Weld Joints Areas
41 12 535 STRIPPING OPERATIONS - REPLACING COMPLETE REAR LUGGAGE

COMPARTMENT FLOOR (TAIL PANEL REMOVED)
2007 BMW 335i
 Remove exhaust system

 Remove heat shield
 Remove carbon canister
 Remove battery
 Remove both backrests
 Remove rear seat
 Remove and install rear left and right wheel arch cover
 Remove left luggage compartment wheel arch panel
 Remove right luggage compartment wheel arch panel
 Partially detach wiring harness and tie to one side
41 12 557 REPLACING LUGGAGE COMPARTMENT FLOOR, MIDDLE SECTION (TAIL PANEL

REMOVED)
Read general service information under BODY, GENERAL.
STRIP DOWN vehicle.
NOTE: Observe new procedure for bonding and riveting (REPAIR STAGE 2).
 (1) Frame, luggage compartment floor
CONSUMABLES REQUIRED - MIDDLE SECTION LUGGAGE COMPARTMENT FLOOR

Material Quantity
Adhesive K5a 1
Punch rivets N5 8
Cleaner R1 1
Sealing compound D1
2007 BMW 335i
Fig. 182: Identifying Frame, Luggage Compartment Floor

Mark severance cuts (1) and cut.
IMPORTANT: Cut only outer plates.
Open weld joints in areas (2) and remove luggage compartment floor (3).
Fig. 183: Identifying Luggage Compartment Floor Severance Cuts And Welding Areas
Mark new part in accordance with severance cuts on vehicle and cut.
2007 BMW 335i
IMPORTANT: Do not grind new parts and body in area of bonding surfaces.
Clean all bonding surfaces (1) on vehicle and on new part with cleaning agent R1.
Apply adhesive K5b to bonding surfaces (1).
Fig. 184: Identifying Bonding Surfaces For Applying Adhesive K5b

Adjust luggage compartment floor (1) to fit in conjunction with TAIL PANEL and secure.
Rivet luggage compartment floor with 6 punch rivets N5 in areas (2).
Fig. 185: Identifying Luggage Compartment Floor And Rivet Areas

2007 BMW 335i
41 12 557 STRIPPING OPERATIONS - REPLACING LUGGAGE COMPARTMENT FLOOR,

MIDDLE (TAIL PANEL REMOVED)

 Partially detach wiring harness and tie to one side.
41 12 560 REPLACING LUGGAGE COMPARTMENT FLOOR (COMPLETE WITH INNER WHEEL

ARCH SECTION, TAIL PANEL REMOVED)
Read contents of Body, general .
Use only approved Spot-Welding Apparatus for repairs!
 (1) Luggage compartment floor, upper section

 (2) Mounting, rollover protection, right
 (3) Mounting, rollover protection, left
 (4) Rear axle carrier
 (5) Wheel arch, rear, inner half, left
 (6) Wheel arch, rear, inner half, right
Fig. 186: Identifying Luggage Compartment Floor, Mounting, Rear Axle Carrier And Wheel Arch
2007 BMW 335i
Fig. 187: Identifying Weld Joint Areas And Holder

Mark severance cut in accordance with measurement a and cut.
Measurement a=40 mm behind support, frame side member (1).
Installation:
Weld in reinforcement plates at severance cuts.

2007 BMW 335i
Fig. 188: Identifying Frame Side Member

Mark severance cut (1) and cut.
Installation:
Weld new components in areas (3) additionally.
Fig. 189: Identifying Cut Mark And Weld Joint Areas

Mark severance cut (1) in accordance with measurement a and cut rear axle carrier.
Measurement a=70 mm from rear axle bushing mounting.
Installation:

2007 BMW 335i
Fig. 190: Identifying Weld Joint Areas


Installation:

2007 BMW 335i

Open adhesive joints in area (2).
Remove rollover protection mounting (3).
Installation:
Plug/spot-weld in area (2) of wheel arch side.
Fig. 193: Identifying Rollover Protection Mounting And Adhesive Joint Area

2007 BMW 335i
Installation:
Set 5 additional welding spots in area (3).

Installation:


2007 BMW 335i

Mark severance cuts (1) in accordance with measurement and cut.
Measurement b = 110 mm
Installation:
The parts separated by cutting are still needed.

2007 BMW 335i
Fig. 197: Identifying Cut Mark

Installation:


2007 BMW 335i
Fig. 199: Identifying Weld Joint Areas And Cut Mark


Installation:
2007 BMW 335i
The parts (2) separated by cutting are still needed.


Installation:
2007 BMW 335i
Weld new components in following order:

 (3) Support, frame side member
 (4) Wheel arch, rear, inner half
 (5) Mounting, rollover protection (not shown)
Fig. 203: Identifying Rear Axle Carrier, Luggage Compartment Floor, Wheel Arch And Mounting
41 12 590 REPLACING LUGGAGE COMPARTMENT FLOOR (COMPLETE WITH LEFT OR

RIGHT INNER WHEEL ARCH SECTION, TAIL PANEL REMOVED)
 Remove mounting for tension strut at rear

 (3) Mounting, rollover protection, left
2007 BMW 335i
 (4) Wheel arch, rear, inner half, left
Fig. 204: Identifying Luggage Compartment Floor, Rear Axle Carrier And Mounting, Rollover
Protection
Fig. 205: Identifying Weld Joint Areas And Holder

Mark severance cut in accordance with measurement a and cut.
Measurement a=40 mm behind support, frame side member (1).
Installation:

2007 BMW 335i
Fig. 206: Identifying Frame Side Member

Mark severance cut (1) and cut.
Installation:

Mark severance cut (1) in accordance with measurement a and cut rear axle carrier.
Measurement a=70 mm from rear axle bushing mounting.

2007 BMW 335i
Installation:


Installation:

2007 BMW 335i

Installation:
Fig. 211: Identifying Weld Joint Areas, Adhesive Joint Area And Rollover Protection Mounting
Installation:

2007 BMW 335i

Installation:

Mark severance cut (1) centrally and cut.
Cut floor pan and cross-member underneath.

2007 BMW 335i

Mark severance cuts (1) in accordance with measurement and cut.
Installation:

2007 BMW 335i
Installation:



2007 BMW 335i

Installation:
The cut part (2) is not needed.
Fig. 219: Identifying Weld Joint Areas And Cut Part


2007 BMW 335i

Installation:
Weld new components in following order:

 (5) Mounting, rollover protection
Fig. 221: Identifying Rear Axle Carrier, Luggage Compartment Floor, Support And Wheel Arch
WHEEL WELLS
2007 BMW 335i
41 14 021 REPLACING FRONT LEFT WHEEL ARCH
Observe procedure for repair stage 3!
Read contents of Body, General.
Strip down vehicle.
 (1) Wheel arch, front

 (2) Support carrier, wheel arch, outer
CONSUMABLES REQUIRED - FRONT LEFT WHEEL ARCH REPLACEMENT

Material Quantity
Adhesive K1 1
Blind rivets N1 56
Punch rivets N5 39
EMC screws 4
Cleaner R1 1
Sealant D1
Fig. 222: Identifying Front Wheel Arch, Outer Support Carrier And Wheel Arch
Removing wheel arch

2007 BMW 335i
Mark severance cut (1) in front of holder (2) and cut (holder (2) remains on vehicle).
Installation note:
Mark severance cut (1) in on new part and cut. Take off holder (2).
Apply sealant to cavity acoustic baffle (4). See (expanded) or (not expanded).
Fig. 223: Identifying Severance Cut With Sealant And Welding Areas


2007 BMW 335i

Installation note:
If equipment compartment partition wall (2) is damaged, cut along line (3).
Mark new part in accordance with severance cut on vehicle + 20 mm extra material and cut.
Bond both parts overlapping and rivet. Depending on accessibility, use punch rivets N4 and blind rivets N3.
Fig. 226: Identifying Welding Areas On Compartment Partition Wall


2007 BMW 335i

Make severance cut on new carrier support part in accordance with severance cut on vehicle.

In areas (1) cut open engine support from opposite side and open welded connections.
In area (2) open welded connections from inside.

2007 BMW 335i
Fig. 229: Identifying Engine Support Welding Areas

Adjust new parts to fit with alignment bracket or universal mount and secure.
In areas (1) to (3), set 6.8 mm dia. holes for blind rivets N1:
 Area (1): 3 holes
Area (2): 8 holes
Area (3): 6 holes
Installation note:
After adhesive has hardened, install 2 EMC screws in areas (1) and (2).
2007 BMW 335i
Fig. 230: Identifying EMC Screws Area

In areas (1) and (2), set 6.8 mm dia. holes for blind rivets N1:
Area (2): 2 holes

In areas (1) and (2), set 6.8 mm dia. holes for blind rivets N1:
 Area (1): 1 hole
Area (2): 7 holes
Installation note:
In area (3) 2 N5 punch rivets are used later.

2007 BMW 335i

In areas (1) to (4), set 6.8 mm dia. holes for blind rivets N1:
Area (2): 2 holes
Area (3): 1 hole
Area (4): 9 holes
Installation note:
After adhesive has hardened install 2 EMC screws in areas (1) and (4).
2007 BMW 335i

Set two 6.8 mm dia. holes for blind rivets N1 in area (1).
Remove all new parts and deburr holes.
Fig. 234: Identifying Carrier Support Welding Areas

IMPORTANT: Structure bonding!
Observe preparation of bonding surfaces.
Installing wheel arch
IMPORTANT: Do not grind/sand new parts in area of bonding surfaces.
Clean bonding surfaces with adhesive cleaning agent R1.
Install new parts and rivet with blind rivets.
In area (1) weld new part for ground connection.
Installation note:
In area (2) 1 N5 punch rivet is used later.

2007 BMW 335i

IMPORTANT: Three-plate connection (1)!

Fig. 236: Identifying Rivet Areas On Wheel Arch

Rivet new parts with blind rivets in areas (1) and (2).

2007 BMW 335i

Installation note:
Vehicles with spring strut dome plate insert:
Different plate inserts are fitted, depending on the model.
 Version (A) riveted or glued

 Version (B) screwed
IMPORTANT: Use only identical plate inserts on both sides of the vehicle.
Riveted version:
If damaged, the plate inserts must always be replaced with glued versions on both sides of the vehicle.
2007 BMW 335i
Fig. 238: Identifying Spring Strut Dome Plate Insert

Glued version:
Adhesive/contact surfaces of plate insert must be free of sealant, final paint coat and underbody protection.
Do not grind off primer.
Use adhesive gun 41 3 102 in conjunction with adhesive K3.
Apply K3 adhesive in areas (1). Do not apply any adhesive in area (2).
Secure plate insert with 3 screws and nuts for 2 hours at min. 20°C.
IMPORTANT: Operational strength is only achieved after 12 hours!
Fig. 239: Identifying K3 Adhesive Applying Areas

41 14 021 STRIPPING OPERATIONS - REPLACING FRONT LEFT WHEEL ARCH

 Remove radiator
 If necessary, remove and install intercooler
2007 BMW 335i

 If necessary, remove intake silencer housing
 Remove left side panel
 Remove left spring strut
 Remove left wishbone
 Remove brake booster
 Remove sill strip
 Release left wiring harness
41 14 502 REPLACING REAR LEFT OUTER WHEEL ARCH SECTION (REAR LEFT SIDE PANEL
REMOVED)
Spot-weld bonding is used on this vehicle. Observe specific procedure .
 (1) Wheel arch, outer, rear

 (2) Reinforcement, B-pillar, inner
 (3) End plate, side frame
Fig. 240: Identifying Wheel Arch, Reinforcement And End Plate

2007 BMW 335i



2007 BMW 335i

Cut severance cut along line (2).
Measurement a = 20 mm from radius
Installation:
For reasons of accessibility, the repair joining sequence differs from the standard joining sequence.
Adjust new part in conjunction with side panel to fit.
Attach new component from outside and weld.

View from below:

2007 BMW 335i

Scribe new part along line (1) with 20 mm overlap to vehicle and cut.
Fig. 246: Identifying New Part Along Line

41 14 511 REPLACING COMPLETE REAR LEFT WHEEL ARCH (REAR LEFT SIDE PANEL
REMOVED)

2007 BMW 335i
 (1) Wheel arch, outer, rear

 (2) Reinforcement, B-pillar, inner
 (3) Mounting, rollover protection
 (5) End plate, side frame
 (7) Support, wheel arch
Fig. 247: Identifying Wheel Arch, Reinforcement, Mounting, Wheel Arch, End Plate And Support

2007 BMW 335i


View from below:

2007 BMW 335i

Installation:
Fig. 252: Identifying Rollover Protection Mounting And Weld Joint Areas
Installation:
Weld new components in area (2) additionally.

2007 BMW 335i
Fig. 253: Identifying Weld Joint Areas And Welding Spots Area
Installation:
Weld new components in area (2) additionally.

Installation:

2007 BMW 335i

SIDE FRAME AND DOOR PILLARS

41 21 510 REPLACING FRONT LEFT DOOR PILLAR (FRONT SIDE PANEL REMOVED) (COUPE)
For stripping and rigging operations, refer to FR number 41 21 510.
1. A-pillar, outer
2. Support carrier, wheel arch, outer
3. Shaped part, support carrier (not shown)
4. Shaped part, A-pillar, inner (not shown)
2007 BMW 335i
Fig. 256: Front Left Door Pillar Components

IMPORTANT: Cut outer plate only for following severance cuts.
Measurement a = approx. 130 mm from edge of rectangular hole.
Measurement b = approx. 160 mm from centerpoint of 12 mm dia. bore.
Installation:
Apply window glass adhesive to Cavity Acoustic Baffles (2).

2007 BMW 335i
Fig. 257: Cavity Acoustic Baffles, Reinforcing Panels And Weld Joint Areas
Measurement a = approx. 150 mm from roof edge.
Measurement b = approx. 80 mm below severance cut a.
Measurement c = approx. 500 mm before hole dia. 20 mm.
Installation:
Sheet panel (2) is needed again to seal cowl.

2007 BMW 335i
Fig. 258: Weld Joint Areas, Sheet Panel And Measurement Areas
IMPORTANT: For following severance cut, do not damage sunroof water drain hose.
Mark severance cut (1) in accordance with measurement and cut.
Fig. 259: Severance Cut Mark And Measurement Area

2007 BMW 335i
Open weld joint in area (1).
IMPORTANT: Do not damage sunroof water drain hose (2).
Fig. 260: Open Weld Joints Areas And Sunroof Water Drain Hose
Roughly cut outer and underlying metal panel in areas (1).
Take off door pillar.
Fig. 261: Door Pillar Metal Panel Areas

Unclip water drain hose for sliding sunroof (1).
Remove reinforcements (3) and (4).

2007 BMW 335i
Installation:
Adjust new components (3) and (4) to fit after lacquer replica application on body.
Also adjust new A-pillar component to fit.
Fig. 262: Sunroof, Weld Joint Areas And Reinforcements

Mark new part in accordance with severance cuts above and cut.
Installation:
Apply window glass adhesive to Cavity Acoustic Baffle (1).
Fig. 263: Cavity Acoustic Baffle Adhesive Areas

Installation:
Apply Adhesive in areas (1).

2007 BMW 335i
Weld in reinforcing panels at all severance cuts.
Fig. 264: Adhesive Application Areas

41 21 510 REPLACING FRONT LEFT DOOR PILLAR (FRONT SIDE PANEL REMOVED)
(CONVERTIBLE)
For stripping and rigging operations, refer to FR number 41 21 510.

 (2) Side frame, outer
2007 BMW 335i
Fig. 265: Identifying Support Carrier And Side Frame

Fig. 266: Identifying Support Carrier Dimension


2007 BMW 335i
Measurement b = approx. 160 mm from centerpoint of 12 mm dia. bore.
Installation:

Measurement a = approx. 175 mm from edge of cowl panel.
Dimension b = approx. 240 mm before bore hole dia. 20 mm.

2007 BMW 335i
Installation:

41 21 540 REPLACING FRONT LEFT OUTER DOOR PILLAR SECTION (CONVERTIBLE)
For stripping and rigging operations, refer to information on BMW KSD CD (FR number 41 32 010).
 Remove front side panel

 (2) Door hinge, top left
2007 BMW 335i
 (3) A-pillar, outer
Fig. 269: Identifying Support Carrier, Door Hinge And A-Pillar

Mark severance cut in accordance with specified measurement and cut.

2007 BMW 335i

Mark severance cut at top in accordance with specified measurement and cut.
Severance cut (1) at bottom through 20 mm dia. bore hole.
Installation:
Installation:
2007 BMW 335i

Installation:
MAG-weld hinge in area (1).
Fig. 273: Identifying MAG-Weld Hinge Area

41 21 930 REPLACING INSIDE LEFT SIDE FRAME (B-PILLAR REINFORCEMENT) (COUPE)

2007 BMW 335i
1. Inner side frame

2. Shaped part, B-pillar, inner (not shown)
3. Shaped part, B-pillar, outer (not shown)
Fig. 274: Inner Side Frame Components

Mark severance cut in radius along line (1) and cut.
Fig. 275: Severance Cut Line And Open Weld Joints Areas
Cut reinforcement plate along line (1).
Measurement a = approx. 58 mm from bottom edge In areas (2), the tube is welded from the rear.
In areas (2), mill holes each to approx. 13 mm and cut MAG weld seams.
2007 BMW 335i
Installation:
Holes (2) are no longer welded.
Fig. 276: Reinforcement Plate Line And Weld Hole Areas

 Apply window glass adhesive to Cavity Acoustic Baffle (2).

2007 BMW 335i
Fig. 277: Weld Joints Areas And Cavity Acoustic Baffles

NOTE: Component is glued in area (2).
Installation:
Apply Adhesive in area (2).

2007 BMW 335i
Fig. 278: Weld Joint And Adhesive Areas

Open weld joints in areas (1) from rear side.
Fig. 279: Weld Joints Areas


Cut reinforcement plate similar to severance cut on vehicle along line (1).
In areas (2), the tube is welded from the rear.

2007 BMW 335i
Fig. 281: Welded Tube From Rear

ROOF OUTER SKIN

41 31 000 REPLACING ROOF OUTER SKIN (NORMAL ROOF)
Refer to repair instruction ROOF OUTER SKIN WITH SLIDE/TILT SUNROOF for procedure and carry
over schematically to the car.
STRIP DOWN vehicle.
Installing roof outer skin
Apply sealing compound in areas (1) analogously to Series.
Fig. 282: Identifying Roof Outer Skin Sealing Applying Areas

41 31 010 STRIPPING OPERATIONS - REPLACING ROOF OUTER SKIN E92 (VERSION

WITHOUT SLIDE/TILT SUNROOF)
2007 BMW 335i
 Disconnect battery
 Remove and install windscreen
 Remove and install rear window
 Remove and install roofliner
 Remove and install left roof trim strip
 Remove and install right roof trim strip
 Remove and install roof aerial
 Remove and install backrest
 Tilt parcel shelf with seat belts towards front
41 31 010 REPLACING ROOF OUTER SKIN (VERSION WITH SLIDE/TILT SUNROOF)
See BODY, GENERAL for general instructions.
STRIP DOWN vehicle.
Observe procedure for REPAIR STAGE 2.
 Roof outer skin, slide/tilt sunroof
Fig. 283: Roof Outer Skin, Slide/Tilt Sunroof

Release 4 screws (1) in roof channel.

2007 BMW 335i
Fig. 284: Roof Channel Screws


Release Adhesive Areas (layout, see next work steps) and remove roof outer skin.
2007 BMW 335i
Installation:
Fit new part on body. Fit windscreen for positioning.
Seal weld seams and screws with sealing compound.
Fig. 286: Adhesive And Sealing Compound Area

Apply sealing compound in areas (1).
Apply Adhesive in areas (2).
41 31 010 STRIPPING OPERATIONS - REPLACING ROOF OUTER SKIN E92 (VERSION WITH
SLIDE/TILT SUNROOF)
 Remove and install windscreen
2007 BMW 335i
 Remove and install roofliner

 Remove and install slide/tilt sunroof
 Remove and install left roof trim strip
 Remove and install right roof trim strip
 Remove and install roof aerial
 Remove and install backrest
 Tilt parcel shelf with seat belts towards front.
DASH COWL
41 32 000 REPLACING LEFT OR RIGHT COWL (COUPE)
 A-pillar, outer
Fig. 287: Outer A-Pillar

Measurement b = approx. 550 mm below severance cut a.

2007 BMW 335i
Installation:
Apply window glass adhesive to Cavity Acoustic Baffle (2).
Fig. 288: Measurement A (Approx. 100 mm) From Roof Edge

41 32 010 REPLACING COMPLETE COWL PANEL (CONVERTIBLE)
Read contents of Body, general.
For stripping and rigging operations, refer to information on BMW KSD CD (FR NUMBER 41 32 010).
Spot-weld bonding is used on this vehicle. Observe specific procedure.

2007 BMW 335i
 Remove front side panel

 (2) A-pillar, outer
Fig. 289: Identifying Support Carrier And A-Pillar


2007 BMW 335i

Open brazed joints in areas (2).
Installation:
FRONT TRIM PANEL

41 33 040 REPLACING FRONT WALL

2007 BMW 335i
 Remove Carrier For Bumper Trim
IMPORTANT: Car must not be driven without the front wall.
Driving without the front wall may damage the body structure.
1. Front panel
2. Headlight holder, left
3. Headlight holder, right
Fig. 292: Front Panel And Headlight Holder Components

Carry over the following work steps symmetrically to the other side of the car.
NOTE: View, front side panel, in direction of travel
Release screw (1).
Tightening torque value for front headlight holder to side panel Sheet metal screw ST4.8X22 thread = 2.5 Nm.
Tightening torque value for front headlight holder to side panel M6 thread = 6 Nm.
2007 BMW 335i
Fig. 293: Screw

Release screws (1).
Tightening torque value for Front panel to support carrier M6 thread = 10 Nm.
Remove front panel (2) together with headlight holder (3).
Replacement:
Release screws (4) and remove headlight holder.
Tightening torque for headlight holder to front panel M6X18 = 6 Nm.
Fig. 294: Screws, Front Panel And Headlight Holder

REAR TRIM PANEL

2007 BMW 335i
41 34 041 REPLACING COMPLETE TAIL PANEL (COUPE)
See BODY, GENERAL for general instructions.
STRIP DOWN vehicle.
Observe procedure for REPAIR STAGE 2
1. Rear trim
Fig. 295: Rear Trim

Fig. 296: Weld And Brazed Joints Areas

2007 BMW 335i
Fig. 297: Weld Joint Areas

MAG weld in areas (1).
Fig. 298: MAG Weld Areas

Installation:
Slide in rear trim (1) from bottom upwards.

2007 BMW 335i
Fig. 299: Slide Rear Trim And Installation Direction

41 340 41 STRIPPING OPERATIONS - REPLACING TAIL PANEL (COUPE)
 Remove and install rear bumper trim

 Remove and install carrier for bumper trim
 Remove and install guide for bumper, rear center
 Remove and install guide for bumper, rear left
 Remove and install guide for bumper, rear right
 Remove both rear lights
 Remove luggage compartment floor trim panel
 Upper tail panel trim
 Remove and install rear lid striker
 Remove right luggage compartment wheel arch panel
 Remove and install battery
 Release wiring harness on tail panel and tie to one side
 Release rear lid seal
41 34 041 REPLACING COMPLETE TAIL PANEL (CONVERTIBLE)
Use only approved spot-welding apparatus for repairs.

2007 BMW 335i
For stripping and rigging operations, refer to information on BMW KSD CD (FR NUMBER 41 34 041).
 (1) Rear trim
Fig. 300: Identifying Rear Trim

Fig. 301: Identifying Weld Joints Area And Brazed Joint Areas

2007 BMW 335i

MAG weld in areas (1).
Fig. 303: Identifying MAG Weld Areas

Installation note:
Slide in rear trim (1) from bottom upwards.

2007 BMW 335i
Fig. 304: Identifying Rear Trim

41 34 041 STRIPPING OPERATIONS - REPLACING TAIL PANEL (CONVERTIBLE)
 Remove rear module

 Remove and install bumper trim
 Remove and install carrier for bumper trim
 Remove and install guide for bumper, rear center
 Remove and install guide for bumper, rear left
 Remove and install guide for bumper, rear right
 Remove both rear lights
 Remove and install luggage compartment trim panel on side panel, left
 Remove and install luggage compartment trim panel on side panel, right
 Remove and install rear lid striker
 Remove and install battery
 Release wiring harness on tail panel and tie to one side
SIDE PANELS
41 35 010 REMOVING AND INSTALLING/REPLACING SIDE PANEL, FRONT LEFT OR RIGHT
Observe Gap Dimensions .

2007 BMW 335i
CAUTION: Do not damage adjoining body parts.
Screw with left-hand thread fitted at upper fastening point of right side
panel on A-pillar.
Risk of damage!
Fig. 305: Front Side Panel Screw Installation Instructions

Interior view of front side panel
Unfasten screws.
Tightening torque value for Front Side Panel To Body M6 Thread = 7.6 Nm.
Installation:
Make sure sliding element (1) is correctly seated.

2007 BMW 335i
Fig. 306: Sliding Element

41 35 101 REPLACING REAR LEFT SIDE PANEL (COUPE)
Read contents of BODY, GENERAL.
STRIP DOWN vehicle.
Observe procedure for REPAIR STAGE 2!
1. Side panel, rear
Fig. 307: Rear Side Panel


2007 BMW 335i
Measurement a = approx. 90 mm from roof edge
Measurement b = approx. 150 mm from edge of roof frame
Measurement c = in center point of 20 mm dia. hole
 Apply window glass adhesive to Cavity Acoustic Baffles (2).

 Weld in Reinforcing Panels at all severance cuts.
Fig. 308: Weld Joint Areas And Cavity Acoustic Baffles

41 35 101 STRIPPING OPERATIONS - REPLACING REAR LEFT SIDE PANEL (COUPE)

2007 BMW 335i

 Remove bumper support
 Remove center bumper guide
 Remove left bumper guide
 Remove tail panel trim
 Remove rear lid
 Remove left rear lid hinge
 Remove left rear lid
 Remove left wheel arch panel
 Remove side frame trim
 Remove and install left side window
 Release rear seat and lay to one side.
 Remove backrest
 Remove left backrest side section
 Remove front left lock striker
 Remove left door mucket
 Remove left door sill cover strip
 Remove left side member trim panel
41 35 101 REPLACING REAR LEFT SIDE PANEL (CONVERTIBLE)
Strip down vehicle.
Observe repair stage 3!
 (1) Side panel, rear
Material Quantity
Adhesive K5b 1
2007 BMW 335i
Blind rivets N3 25
Punch rivets N4 22
Punch rivets N5 5
Cleaning agent R1 1
Sealant D1
EMC screws 3
Fig. 309: Identifying Side Panel, Rear

Removing side wall:
IMPORTANT: Before loosening the wheel arch welding connections:
Straighten wheel arch edge similarly to new part.
Open brazed joint in area (2).

2007 BMW 335i
Fig. 310: Identifying Weld Joint Areas And Brazed Joint Area

2007 BMW 335i
Open MIG soldered joints in area (1).
Installation:
MAG-weld new part in area (1).
Fig. 313: Identifying MAG-Weld Area

Installation:
When sealing in area (2), ensure sufficient clearance for outer window cavity cover strip.
2007 BMW 335i
Fig. 314: Identifying Brazed Joint Area And Sealing Area

Adjust new part to fit with alignment bracket or universal mount and secure.
In areas (1) and (2) set 4.2 mm dia. bore holes for blind rivets:
Area Number
1 6
2 4
2007 BMW 335i
Fig. 315: Identifying Bore Hole Areas For Blind Rivets

Set two 4.2 mm diameter bore holes for blind rivets in area (1).
Fig. 316: Identifying Bore Hole Area For Blind Rivets

In areas (1) and (2) set 4.2 mm dia. bore holes for blind rivets:
2007 BMW 335i
Area Number
1 6
2 1
Fig. 317: Identifying Bore Hole Areas For Blind Rivets

Set six 4.2 mm diameter bore holes for blind rivets in area (1).
Fig. 318: Identifying Bore Hole Area For Blind Rivets

IMPORTANT: Do not grind/sand new part in area of bonding surfaces.
Apply adhesive in areas (1).
Adhesive must be applied to new part in area (2).

2007 BMW 335i
Fig. 319: Identifying Adhesive Application Areas

Fit the side wall with alignment bracket or universal mount.
Install side panel with a second person helping.
NOTE: When installing side panel, make sure there is sufficient adhesive on bonding
surfaces.
Secure side wall with gripping pliers.
Rivet side wall with blind rivets in areas (1).
Use punch rivets in areas (2) and (3).
In area (4), secure side wall with gripping pliers until adhesive has hardened.
Area Number Remarks

2 5 Punch rivet N5
3 10 Punch rivet N4
2007 BMW 335i
Fig. 320: Identifying Rivet Areas (1 Of 2)

Rivet side wall with blind rivets in areas (1).
In areas (2) to (4) use punch rivets N4.
Fig. 321: Identifying Rivet Areas (2 Of 2)

2007 BMW 335i
Area Number
2 4
3 2
4 3
5 3
IMPORTANT: The wheel arch must be flanged immediately after riveting before the adhesive
hardens.
After adhesive has hardened, install one EMC screw in each case in areas (1).
Additionally, install EMC screw in sill area.
Fig. 322: Identifying Areas For EMC Screws

41 35 101 STRIPPING OPERATIONS - REPLACING REAR SIDE PANEL, LEFT (CONVERTIBLE)
 Disconnect negative battery cable (job number: 61 20 900)

 Remove bumper trim panel (job number: 51 12 156)
 Remove bumper support (job number: 51 12 050)
 Remove center bumper guide (job number: 51 12 825)
 Remove left bumper guide (job number: 51 12 828)
 Remove tail panel cover (job number: 51 46 050)
 Partly release tailgate seal
 Remove left rear light (job number: 63 21 180)
2007 BMW 335i

 Remove left luggage compartment wheel arch panel (job number: 51 47 151)
 Remove left rear wheel arch cover (job number: 51 71 041)
 Remove side frame trim (job number: 51 13 280)
 Remove side trim panel upper section (job number: 51 43 012)
 Remove rear side trim panel (job number: 51 43 009)
 Remove front door (job number: 41 51 080)
 Remove backrest (job number: 52 24 010)
 Remove left lock striker (job number: 51 21 003)
 Remove left door edge protection (job number: 51 72 000)
 Remove left door sill cover strip (job number: 51 47 030)
 Remove left side member trim panel (job number: 51 71 447)
41 35 102 REPLACING REAR LEFT SIDE PANEL (PARTIAL REPLACEMENT BEHIND WHEEL
ARCH) (CONVERTIBLE)
Use only approved spot-welding apparatus for repairs.
 (1) Side panel, rear
Fig. 323: Identifying Side Panel, Rear

Mark severance cut (1) in accordance with measurement a and cut.
Measurement a =240 mm from corner of side panel

2007 BMW 335i

Fig. 325: Identifying Weld Joint Areas And Brazed Joint Areas

2007 BMW 335i
Fig. 326: Identifying Weld Joint Areas And Brazed Joint Areas

Mark new part in accordance with severance cut (1) on car and cut.

2007 BMW 335i

Installation note:
Procedure deviating from standard:
Make 15 mm wide reinforcement plate (1).
Adjust new part (2) to fit in conjunction with rear lid.
Bring reinforcement plate from inside into contact with side panel.
Set tacking points in area of severance cut (3) from outer side. In so doing, exert pressure from inner side on
reinforcement plate to enlarge gap at severance cut (3) by approx. 0.5 mm. This reduces warpage in the welding
area.
Weld severance cut completely.
Fig. 329: Identifying Reinforcement Plate

2007 BMW 335i
FRONT SIDE DOORS

41 5.... ADJUSTING DOOR
CAUTION: Do not damage adjoining body parts.
Minor corrections (realignment work) are permitted if the existing

adjustment options are not sufficient.
NOTE: Observe Gap Dimensions .
The door must be provided with all attachment parts for correct adjustment.
Adjust screwed body parts from rear to front.
The following illustrations are schematic representations and are to be applied

to the relevant vehicle type.
Slacken lock striker, remove if necessary.
Slacken nuts (1) until door can still just be moved.
Tightening torque value for front door M8 thread = 20 Nm.
Fig. 330: Lock Striker And Nuts

Adjust rear door in transition to front door (Y) by fitting shims.
Installation:
To preset new part, carry over number of shims from damaged door.
2007 BMW 335i
Adjust door longitudinally (X) and vertically (Z).
Fig. 331: Door And Shims

Check that adjoining body parts are flush in terms of height and correct if necessary.
NOTE: Vertical adjustment of door must not be influenced by lock striker.
When the door is closed, the lock striker must not touch or scrape against the
door lock. Look out for scratches.
2007 BMW 335i
Fig. 332: Vertical Door Alignment

Slacken screws (1) until lock striker can still just be moved.
Move lock striker sideways in order to adjust transition between door and rear side panel.
For tightening torque refer to 51 21 2AZ in 51 21 FRONT DOOR LOCKS .
NOTE: When the door is closed, the lock striker must not touch or scrape against the
door lock. Look out for scratches.
Fig. 333: Lock Striker Screws

After installation:
 Tighten all screws and nuts to specified torque.

 Touch up unpainted surfaces in the appropriate color.
 If necessary, adjust front door.
2007 BMW 335i
41 5.... REMOVING AND INSTALLING DOOR
IMPORTANT: Do not damage adjoining body parts.
The illustrations are schematic representations and are to be applied to the relevant vehicle type.
Open door.
Release screw on connector frame.
Tightening torque for front door plug connection to body M5X16 = 3 Nm.
Fig. 334: Connector Frame Screw

NOTE: Secure door against closing.
Release screw (1) on door retainer.
Front door:

2007 BMW 335i
Fig. 335: Door Retainer Screws

IMPORTANT: Secure door against falling out.
Release screws between both hinge elements at top and bottom.
Pull both screws out of hinges.
Tightening torque for front door hinge pin M10x1.25 = 25 Nm.
Fig. 336: Hinge Elements Pins

Pull out door sideways and place it on a suitable surface.

2007 BMW 335i
Fig. 337: Door Removal Direction

Pull plug connection from door pillar, unlock by pulling out bar and detach.
Installation:
If necessary, adjust door .
Fig. 338: Plug Connection And Removal/Installation Directions

REPLACING DOOR
IMPORTANT: For production reasons the side impact beam is only screwed loosely.
Tighten screws of side impact beam.
41 51... REPLACING DOOR HINGE BUSHING (DOOR REMOVED)

2007 BMW 335i
 41 1 150
 41 1 151
 41 1 152
Special tool kit 41 1 150 comprises:
Bushing 41 1 151
Bolt 41 1 152

Cut off hinge bushing in area (1) with chisel.
Drive out remainder of hinge bushing with punch.
Fig. 340: Hinge Bushing Area

2007 BMW 335i
Insert bolt 41 1 152 with new hinge bushing (2) into hinge.
Screw bushing 41 1 151 with flat end (3) pointing upwards onto bolt 41 1 152 .
Turn bushing 41 1 151 until taper (1) borders hinge bushing (2).
Screw off bushing 41 1 151 again.
Fig. 341: Hinge Bushing, Taper, Flat End, Special Tools (41 1 151) And (41 1 152)
Twist bushing 41 1 151 with flat end (1) onto bolt 41 1 152 .
Turn bushing 41 1 151 until gap dimensions (2) are identical.
Fig. 342: Flat End, Gap Dimensions, Special Tools (41 1 151) And (41 1 152)
2007 BMW 335i
FRONT LID
41 61 014 ADJUSTING ENGINE COMPARTMENT LID
The specified Gap Dimensions serve as the basis for the adjustment procedure.
Make unpainted surfaces visible by also moving the hinges.
Touch these up in the appropriate color.
Loosen screws (1) and (2) on left and right hinges.
Hood lid must be able to be moved.
NOTE: If the adjustment range is not sufficient, release retaining screws of engine
hood hinge on body and move hinge.
Fig. 343: Left And Right Hinges Screws

Locks and retaining hook must snap correctly into place.
Adjust engine hood.
NOTE: Vertical Adjustment of engine hood to side panel by means of stop pads.
2007 BMW 335i
Fig. 344: Locks And Retaining Hook

NOTE: Height adjustment of hood lid to front wall:

Release screw (1) and remove cover (2).
Height adjustment by turning at closing hooks (3).
Fig. 345: Cover, Screw And Closing Hooks

Tighten down all screw connections again.
Tightening torque for Engine bonnet/hood to bonnet/hood hinge M8 thread = 15 Nm..
IMPORTANT: Check function of retaining hook.
41 61 014 ADJUSTING ENGINE COMPARTMENT LID (FOR VEHICLES WITH ACTIVE

PEDESTRIAN PROTECTION AFGS)
2007 BMW 335i
The BATTERY EARTH LEAD must be clamped off on vehicles with AFGS
active pedestrian protection!
The specified Gap Dimensions serve as the basis for the adjustment procedure.
Minor corrections (realignment work) are permitted if the existing adjustment options are not sufficient.
Disconnect BATTERY EARTH LEAD .
NOTE: Stop screw must not be damaged or missing. If necessary, replace engine
compartment lid hinge.
The stop screw is preset and must not be used to adjust the engine
compartment lid!
Fig. 346: Locating Stop Screw

Loosen screws (1) and (2) on left and right hinges.

2007 BMW 335i
Engine compartment lid must be able to be moved.
NOTE: If adjustment range is not sufficient, slacken screws on body and slide hinge.

Locks and retaining hook must engage correctly.
Adjust engine compartment lid.
Fig. 348: Locating Engine Hood/Bonnet Adjustment Area

Height adjustment at hinge:
Slacken screws (1) and adjust engine compartment lid.

2007 BMW 335i
Fig. 349: Identifying Screws For Height Adjustment At Hinge

Height adjustment at strikers:
Height adjustment by turning at closing hooks (3).
Height adjustment of engine compartment lid to side panel by means of stop pad.
NOTE: The engine compartment lid is correctly adjusted in the front section by a
combination of pulling the strikers and pressing the stop pads.
Incorrect adjustment results in either wobbling of the engine compartment lid or

sluggish unlocking.
Fig. 350: Identifying Height Adjustment Of Hood Lid To Front Wall

2007 BMW 335i
IMPORTANT: Check function of retaining hook.
After setting:
 Tighten all screws and nuts to specified torque.

 Refer to TIGHTENING TORQUES .
 Touch up unpainted surfaces in the appropriate color. If necessary, adjust front side panels.
41 61... CHECKING HINGE FOR ENGINE COMPARTMENT LID (FOR VEHICLES WITH ACTIVE
PEDESTRIAN PROTECTION SYSTEM)
 Remove hinge for engine compartment lid
Open and close hinge (1).
Place hinge (1) on a level surface.
Check holes (2) for dimensional accuracy relative to support.
Dimension a=32 mm
Test result Solution

Hinge is stiff Replace hinge
Faulty dimensional accuracy Replace hinge
Fig. 351: Checking Hinge For Engine Compartment Lid

2007 BMW 335i
41 61 000 REMOVING AND INSTALLING ENGINE COMPARTMENT LID
 Disconnect all cable plug connections
IMPORTANT: For the following work step, secure the engine hood against falling closed.
Disconnect gas-pressure damper from engine hood (1).
Loosen screws (2).
Release screws (3).
Tightening torque.
NOTE: This work step must be carried out with a second person assisting.
Fig. 352: Gas-Pressure Damper From Engine Hood

Remove hood lid.
Installation:
Install engine hood at screw locations to on hinge. This dispenses with the need for adjustment after installation.
If this is not possible, Adjust Engine Hood .
41 61 010 REMOVING AND INSTALLING ENGINE COMPARTMENT LID (ACTIVE PEDESTRIAN

PROTECTION AFGS)
2007 BMW 335i
The BATTERY EARTH LEAD must be clamped off on vehicles with AFGS
active pedestrian protection!
IMPORTANT: Adhere to the following safety information so as to avoid a danger of injury by

the actuator:
- Support engine compartment lid in fully opened position with suitable

apparatus.
- Removal of the engine compartment lid must be carried out with the
assistance of a second person.
Follow instructions on ACTIVE PEDESTRIAN PROTECTION SYSTEM.
Disconnect NEGATIVE BATTERY CABLE .
Release GAS PRESSURE SPRING on engine compartment lid.
Unscrew nuts (1).
Remove engine compartment lid.
Installation note:
Install engine compartment lid at screw locations to on hinge.
Tightening torque: 15 Nm.
If necessary, ADJUST ENGINE COMPARTMENT LID.

2007 BMW 335i

41 61 571 REMOVING AND INSTALLING/REPLACING LEFT HINGE FOR ENGINE

COMPARTMENT LID, (FOR VEHICLES WITH ACTIVE PEDESTRIAN PROTECTION AFGS)
WARNING: Adhere to the following safety information so as to avoid a danger of

injury by the actuator:
The BATTERY EARTH LEAD must be clamped off prior to work on the
hinge or engine compartment lid!
Risk of injury.
Support engine compartment lid in fully opened position with suitable

apparatus.
Remove ENGINE COMPARTMENT LID.
Release bolt (2) and remove actuator (3).
Release screws (4) and remove hinge.

2007 BMW 335i
Installation note:
ADJUST hinge together with engine compartment lid.
Fig. 354: Removing/Installing Left Hinge For Engine Compartment Lid (Vehicles With Active Pedestrian
Protection)
51 23 400 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT ACTUATOR (ACTIVE

PEDESTRIAN PROTECTION)
WARNING: Adhere to the following safety information so as to avoid a danger of

injury by the actuator:
The BATTERY EARTH LEAD must be clamped off prior to work on the
actuator or engine compartment lid!
Do not exert any force on the actuator.
Incorrect handling may result in triggering of the actuator and thereby

cause serious injury.
Remove COWL PANEL COVER .
Lever out clip (1).
Release screws (2) and remove cavity sealing (3).

2007 BMW 335i
Fig. 355: Identifying Clip, Screws, And Cavity Sealing

Comply with notes regarding HANDLING ACTIVE PEDESTRIAN PROTECTION.

2007 BMW 335i
Fig. 356: Identifying Actuator, Bolt, And Connector

REAR LID
41 62 000 REMOVING AND INSTALLING REAR LID (COUPE)
 Remove Panel For Rear Lid

 Disconnect all plug and socket cable connections on rear lid.
Slacken screws (1)
Tightening torque for rear lid to rear lid hinge M8 thread = 15 Nm..
Remove rear lid.

2007 BMW 335i
Installation:
Adjust Rear Lid .
Fig. 357: Rear Lid Screws

41 62 000 REMOVING AND INSTALLING REAR LID (CONVERTIBLE)
 Remove trim panel for rear lid
Release bolts (1).
Tightening torque: 20 Nm
Remove rear lid.
Installation note:
 Install rear lid at screw locations on hinge.
This dispenses with the need for adjustment after installation.
If necessary, adjust rear lid.

2007 BMW 335i
Fig. 358: Identifying Bolts

41 62 014 ADJUSTING REAR LID (COUPE)
The Gap Dimensions serve as the basis for adjustment work.
Make unpainted surfaces visible by also moving the hinges. Touch these up in the appropriate color.
Slacken screws (1) and (2) on rear lid hinge to rear lid until such stage that rear lid can still be moved.
Adjust rear lid.
Retighten all screws.
Tightening torque for rear lid to rear lid hinge M8 thread = 20 Nm.
Fig. 359: Rear Lid Screws

2007 BMW 335i
Adjusting height of rear lid in relation to side panel:
Slacken screws (1) on rear lid hinge to side panel until such stage that rear lid can still be moved.
Adjust rear lid.
Tightening torque rear lid hinge to body M8 thread = 20 Nm..
Adjust Rear Lid Lock .
Fig. 360: Rear Lid Screws And Hinge

41 62 014 ADJUSTING REAR LID (CONVERTIBLE)
NOTE: Following components must be correctly fitted and adjusted:
 Convertible top compartment lid
The gap dimensions serve as the basis for adjustment work.
Slacken screws (1) on rear lid hinge to rear lid until such stage that rear lid can still be moved.
2007 BMW 335i
Adjust rear lid vertically and lengthways.
NOTE: If lateral adjustment is necessary, it is essential to adjust the convertible top

compartment lid; carry out this adjustment if necessary.
Only then carry out lateral adjustment with spacer plates on rear lid hinge.
Fig. 361: Identifying Slacken Screws

Adjust rear lid lock .
Adjust bump stops .
41 62 520 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT HINGE FOR REAR LID
(REAR LID REMOVED)
Release screws (1).
Tightening torque for Rear lid hinge to body M8 thread = 20 Nm..
Remove hinge (2).
Adjust rear lid on the basis of the Body Gap Dimensions .
Replacing hinge only:
Remove Gas-Filled Strut for rear lid.

2007 BMW 335i
Fig. 362: Rear Lid Screws And Hinge

OTHER FLAPS
41 63 000 REMOVING AND INSTALLING FLAP FOR FUEL FILLER NECK

Open fuel filler flap.
Lever out lock (2) and detach fuel filler flap (1) in direction of arrow.
Fig. 363: Fuel Filler Flap, Lock And Removal Direction

41 63 003 REPLACING COVER BOWL (COUPE)

2007 BMW 335i
 Remove right Rear Wheel

 Remove rear right Wheel Arch Trim
 Remove Flap For Fuel Filler Neck
 Remove Servodrive For Tank Filler Flap
IMPORTANT: Deformation of the sheet metal flanges in the side panel and the wheel arch
results in permanent vehicle leakage. Carry out removal/installation with great
care.
1. Filler bowl
Fig. 364: Filler Bowl

Turn sleeve (1) through approx. 45° and pull out in direction of arrow.
Fig. 365: Sleeve And Removal Directions

2007 BMW 335i
Press retaining strap (1) inwards and lift out (see arrow).
Pierce cover bowl at markings (3) with a small screwdriver.
Remove cover (2).
Fig. 366: Retaining Strap, Cover, Cover Bowl Markings And Removal Direction
NOTE: Illustrations shows fuel filler pipe removed.
Release rubber seal from sheet metal flange.
Fig. 367: Rubber Seal Removal Directions

Insert screwdriver to a depth of max. 5 mm and unlock cover bowl catch.

2007 BMW 335i
Fig. 368: Cover Bowl Catch And Screwdriver

Keep cover bowl tensioned with pliers (2).
Unlock catches individually with screwdriver (1).
Unlock catches in following order:
1. Top left
2. Bottom left
3. Top right
4. Bottom right
Move screwdriver in opposite direction at both lower catches.
Fig. 369: Cover Bowl, Pliers, Screwdriver And Removal Directions

Open hinge arm (1).

2007 BMW 335i
IMPORTANT: Do not damage sheet metal flange of side panel.
Carefully twist out cover bowl (2) at first at rear in direction of arrow from side panel and remove.
Fig. 370: Hinge Arm, Cover Bowl And Removal Direction

Installation:
Open hinge arm.
Turn sealing sleeve in area of hinge inwards and hold.
Insert cover bowl and engage sealing sleeve over fuel filler pipe.
Fig. 371: Hinge Arm Opening Direction

Installation:
Using fitting aid (1), pull sealing lip (2) over sheet metal flange of wheel arch (3).
2007 BMW 335i
Fig. 372: Fitting Aid, Sealing Lip, Wheel Arch Metal Flange And Installation Direction
Installation:
Illustrations shows fuel filler pipe removed.
Check that sealing lip is correctly seated.
Fig. 373: Sealing Lip

Installation:
Cover bowl must snap into place 4 times.
After installing, carefully check cover bowl at clips for secure seating.
There must be no discernible gap between sealing lip and side panel in area (1).
2007 BMW 335i
Fig. 374: Sealing Lip And Side Panel Area

41 63 003 REPLACING COVER BOWL (CONVERTIBLE)
 Remove Flap For Fuel Filler Neck

 Remove Servodrive For Tank Filler Flap
IMPORTANT: Deformation of the sheet metal flanges in the side panel and the wheel arch
results in permanent vehicle leakage. Carry out removal/installation with great
care.
 (1) Filler bowl
Fig. 375: Identifying Filler Bowl

2007 BMW 335i
Press retaining strap (1) inwards and lift out (see arrow).
Pierce cover bowl at markings (3) with a small screwdriver.
Remove cover (2).
Fig. 376: Identifying Retaining Strap And Cover

Lift rubber collar (1) over plastic tabs in areas (2).
Release rubber collar (1) from cover bowl (3) by pressing inward.
NOTE: Rubber collar (1) remains attached to vehicle.
Fig. 377: Identifying Rubber Collar, Plastic Tabs And Cover Bowl
Insert screwdriver to a depth of max. 5 mm and unlock cover bowl catch.

2007 BMW 335i
Fig. 378: Unlocking Cover Bowl Catch

Keep cover bowl tensioned with pliers (2).
Unlock catches individually with screwdriver (1).
Unlock catches in following order:
1. Top left
2. Bottom left
3. Top right
4. Bottom right
Move screwdriver in opposite direction at both lower catches.
Fig. 379: Unlocking Catches With Screwdriver

Close hinge arm (1).

2007 BMW 335i
IMPORTANT: Do not damage sheet metal flange of side panel.
Carefully twist out cover bowl (2) at first at rear in direction of arrow from side panel and remove.
Fig. 380: Identifying Hinge Arm And Cover Bowl

Installation:
Fit approx. 0.5 m long cable (1) in groove on rubber collar (2).
Fig. 381: Identifying Cable And Rubber Collar

Installation:
Install cover bowl (1).
Thread ends of cable (2) outwards.

2007 BMW 335i
Align bottom rubber collar (3) with recess (see arrow).
Pull rubber collar (3) over the cover bowl by pulling the ends of cables (2).
Fig. 382: Identifying Cover Bowl And Rubber Collar

Installation:
Slowly pull out cable ends (2).
Press rubber collar (1) into groove with special tool 00 9 321.
Fig. 383: Identifying Rubber Collar And Cable Ends

Installation:
Cover bowl must snap into place 4 times.
After installing, carefully check cover bowl at clips for secure fit.
2007 BMW 335i
There must be no discernible gap between sealing lip and side panel in area (4).
Check secure fit of rubber collar (1) in areas (2).
Fig. 384: Identifying Rubber Collar

41 63 060 REMOVING AND INSTALLING CONVERTIBLE TOP COMPARTMENT LID
 Connect charger.
 Open rear end module.
Clip special tool 54 0 240 onto hydraulic cylinder on left and right.
IMPORTANT:  The opening in the assembly support must face towards the rear of the
vehicle.
 Risk of damage!
Remove special tool after completing work.

2007 BMW 335i
Fig. 385: Identifying Special Tool Onto Hydraulic Cylinder

Open rear lid with ignition key.
Fig. 386: Opening Rear Lid With Ignition Key

Tape off rear lid (1) in area shown (2) on both sides with plastic adhesive tape.
2007 BMW 335i
Fig. 387: Identifying Rear Lid

Pay attention to spacer plates.
Release screws (2). Tightening torque: 20 Nm
Remove convertible top compartment lid (3).
Installation note:
 To pre-adjust, mount the convertible top compartment lid at the screw impressions on the hinge.
Adjust convertible top compartment lid.
Fig. 388: Identifying Convertible Top Compartment Lid And Screw

41 63 068 ADJUSTING CONVERTIBLE TOP COMPARTMENT LID

2007 BMW 335i
The E93 gap dimensions serve as the basis for adjustment work.
Connect charger.
NOTE: Carry out adjustment first vertically, then longitudinally and laterally.
Work sequence starts with convertible top closed.
Height adjustment
Open convertible top compartment lid (3).
Slacken nuts (2). Pay attention to spacer plates (1).
Adjust convertible top compartment lid (3) to side panels by means of spacer plates (1).
Fig. 389: Identifying Convertible Top Compartment Lid And Screw

Longitudinal and lateral adjustment
Open convertible top until rear module (1) is opened approx. 10 cm.
Stop opening operation in the position shown.

2007 BMW 335i
Fig. 390: Identifying Rear Module

Close rear end module (1) again.
Stop closing operation when the coupling fastener has locked the rear end module (1).
The correct position is reached when the rear end module (1) is flush with the side panel in area (2). If
necessary, repeat procedure.
Fig. 391: Identifying Rear End Module And Side Panel

NOTE: In event of excessive height difference between convertible top compartment lid
and rear lid in area shown:
Tilt convertible top compartment lid in rear area downwards.
To do so, remove spacer plates from middle and rear screw fastening points, see next picture.
2007 BMW 335i
Fig. 392: Identifying Spacer Plates

IMPORTANT: For purposes of clarity, picture shows and description refers to the opened
convertible top compartment lid.
However, adjustment in the longitudinal direction and to the side is carried out
with the convertible top compartment lid closed from the luggage
compartment.
Open rear lid with ignition key.
Slacken nuts (2).
Adjust convertible top compartment lid (3) longitudinally and laterally.
Tighten down nuts (2).
Fig. 393: Identifying Convertible Top Compartment Lid And Nuts

2007 BMW 335i
51 71 360 REMOVING AND INSTALLING/REPLACING SEAL FOR TAILGATE (COUPE)
IMPORTANT: To prevent water ingress, removed sealing may not be reused.
 Remove OUTER LEFT AND RIGHT WEATHERSTRIP

 Remove left and right LUGGAGE COMPARTMENT WHEEL ARCH PANELS
The right side is removed in the same way as the left side.
Feed out front seal (1) and remove by pulling backwards.
Reposition convertible top module if necessary to completely remove seal (1).
Installation note:
 Observe fitting of seals
Fig. 394: Identifying Seal And Screws

Replacement
To avoid water entering the vehicle interior, the new seal (1) must be modified as follows:
Remove marked section of lip (2).
(Larger frame section, see next step)

2007 BMW 335i
Fig. 395: Identifying New Seal And Marked Section Of Lip

Dimension "X" = 40 mm
Cut section in direction "a" -> "b" with sharp knife.
WARNING: The seal itself must not be damaged.
Therefore make sure you leave a bridge between the cut at the lip (dashed
line) and the transition of the lip to the seal (dot-dash line).
Fig. 396: Identifying Cutting Area

51 71... REPLACING CONVERTIBLE TOP COMPARTMENT LID SEAL
See REPLACING SOFT TOP COMPARTMENT LID GASKET .

2007 BMW 335i
ACCESSORIES AND EQUIPMENT Body Equipment - Repair Instructions
Body Equipment - Repair Instructions
GENERAL
51 00... NOTES ON COMPONENT BONDING ADHESIVE TAPE
1. General notes
 Bonding at room and object temperature of >+18°C.

 Newly painted parts may only be bonded after a drying time of at least 24 hours.
 Optimal bonding/attachment to the background surface is achieved after approx. 48 hours. Components
must not be exposed to mechanical strain beforehand (car wash, strength test, etc.).
 Do not touch bonding surface.
 It is not the length of time that pressure is applied but rather the force of pressure applied that is crucial.
 Detaching the adhesive tape after pressing destroys the adhesive layer.
 After being pressed on gently, adhesive tape can be pulled off again up to 3 times.
2. Auxiliary materials and tools
 CLEANING AGENT R1 OR CLEANING AGENT R2

 Fluff-free cleaning cloths
 Pressure roller
3. Preparations
 Remove all adhesive residue or clean new part thoroughly

 Clean the areas to be bonded immediately before bonding to remove silicone and grease residues.
NOTE: Observe air drying time =1 minute.
4. Bonding
4.1 Components without pre-fitted adhesive tape
 Pull off liner* from adhesive tape

 Position adhesive tape on component and stick on
 Press down adhesive tape over entire adhesive area
 Continue with Point 4.2
* Liner is the protective film on the adhesive tape
4.2 Components with pre-fitted adhesive tape

2007 BMW 335i
 Pull off liner* from adhesive side (if adhesive area is large, do not pull off liner completely)
 Align component in correct position on vehicle
 Press down component over entire adhesive area
51 00... NOTES ON BONDING/ATTACHING COMPONENTS WITH DOUBLE-SIDED ADHESIVE

TAPE
1. General notes
 Bonding at room and object temperature of 18 to 25 °C.
 Newly painted parts may only be bonded after a drying time of at least 24 hours.
 Optimal bonding/attachment to the background surface is achieved after approx. 48 hours.

Components must not be exposed to mechanical strain beforehand (car wash, strength test, etc.).
 Do not touch bonding area.
 It is not the length of time that pressure is applied but rather the level of pressure applied that is
crucial.
 Detaching the adhesive tape after pressing destroys the adhesive layer.
 After being pressed on gently, adhesive tape can be pulled off again up to 3 times.

 Spirit, fluff-free cleaning cloths
 Pressure roller
3. Preparations
 Remove all remnants of adhesive or clean new part thoroughly
 Clean the areas to be bonded with spirit immediately before bonding to remove silicone and grease
residues.
NOTE: Observe ventilation time > or = 1 minute.
4. Bonding
1. Components without pre-fitted adhesive tape
 Pull off liner* from adhesive tape.
 Position adhesive tape on component and stick on.
 Press down adhesive tape over entire bonding area.
 Continue with Point 4.2
2. Components with pre-fitted adhesive tape

 Pull off liner on adhesive side.
 Align component in correct position on vehicle.

2007 BMW 335i
 Press down component over entire bonding area.
51 00... NOTES ON FITTING WINDOW GUIDE SEALS
1. Safety at work
 Wear protective goggles, protective gloves and if necessary an apron.
 Do not eat, drink or smoke in the area of processing/application
 Ensure rooms are well ventilated.
 Keep heat and ignition sources well away
 In event of skin contact: Wash areas of skin affected with soap and water immediately, change
work clothing which has been fouled with anti-friction agent immediately (keep spare work
clothing in reserve)
 In event of eye contact: Rinse eyes immediately with plenty of water and seek medical advice
 Observe safety data sheet (see Aftersales Assistance Portal (ASAP) - Service/Technology - Safety
Data Sheet - 7-digit part number)
2. General notes
 Use only BMW-approved anti-friction agents for fitting
 Application only at room and object temperatures between 18 and 25 °C
 Anti-friction agent dries after fitting and becomes sticky
 Anti-friction agent can only be used for fitting and not for fault elimination (e.g. grating)
 Freshly painted parts may only be glued after a minimum drying time of 24 hours
 Optimal attachment of the film to the background surface is achieved after approx. 48 hours. Film
must not be exposed to mechanical strain beforehand (car wash, strength test, etc.).
IMPORTANT: To avoid grating noises, do not use soapy water (low-surface-tension

water with washing-up liquid) or anti-friction agent containing silicone

 Spirit, cleaning cloth, plastic squeegee, needle
 Anti-friction agent G13 (manufactured by Zestron) part no. 83 23 0441 032
4. Preparations
 Heat and remove adhesive residues with a hot air blower or clean new part thoroughly
 Immediately prior to fitting, clean the areas to be glued with spirit in order to remove silicone and
grease residues
NOTE: Air drying time approx. 1 minute
5. Installation
 Apply anti-friction agent to reverse side of seal only
 Perform fitting within 10 minutes of applying anti-friction agent
 Anti-friction agent dries after fitting and becomes sticky

2007 BMW 335i


function is active.

Fig. 1: Identifying Automatic Engine Start/Stop Button (MSA)

 Workshop mode
A = 10 mm
B = 7 mm
To make sure that the engine hood/bonnet contact is at the basic setting, if necessary press the hood/bonnet
contact up to the limit position before starting work and slowly release.
2007 BMW 335i
Fig. 2: Identifying Basic Setting And Workshop Mode For Engine Hood/Bonnet
51 00... SAFETY INSTRUCTIONS FOR WORKING ON CARS WITH AIRBAG SYSTEMS
WARNING: If work is carried out in area of airbag systems, e.g. on:
 Door trim panels

 Interior trims
 Instrument panel etc.
the ignition must be turned off in each case.
 The ignition must always be off.

 The ignition key must be removed from the ignition lock.
This eliminates the risk of injury.
51 00... SERVICE POSITION OF ENGINE COMPARTMENT LID
 51 0 040
 51 2 160
 51 2 170
 51 2 180
 51 2 240
2007 BMW 335i
NOTE: Only the special tool pertaining to the model series can be selected.
MODEL SERIES AND SPECIAL TOOLS REFERENCE

Model series Special tool
E46, R50, R52, R53 51 2 160
E53, E60, E61, E63, E64, E81, E85, E86, E87, E90, 51 2 170
E91, E92, E93
E65, E66, E67 51 2 180
E83 51 0 040
E70 51 2 240
WARNING: Risk of injury and damage!
Engine hood/bonnet must be held by a second person helping.
NOTE: The illustrations below serve as examples for all corresponding vehicles.
The operation is described on the left side; proceed in the same way for the
right side.
Special tool can only be used on housing (1) of gas spring strut (thick part).
NOTE: Gas spring strut can also be installed the other way round (housing on
hood/bonnet).
Special tool can be used in both directions.
Fig. 3: Gas Spring Strut Housing

Release gas spring strut on left/right housing side.
Slide special tool (1) over housing (2) of gas spring strut.
2007 BMW 335i
Clip ball socket of special tool on ball stud.
Proceed in same way on other side.
Fig. 4: Gas Spring Strut Housing, Special Tool And Removal Direction
FRONT BUMPER
51 11.. OVERVIEW OF FRONT BUMPER
2007 BMW 335i
Fig. 5: Identifying Front Bumper Components

51 11... INSTALLING/REPLACING NUMBER/LICENSE PLATE (WITHOUT BASE)
Initial fitting:
Place drilling hole template (1) on bumper (2).
NOTE: Hole diameter = 2.5 mm (see template).
Drill holes according to number/license plate.
Remove template (1) and secure number/license plate with screws provided.
For tightening torque refer to 51 11 3AZ in 51 11 FRONT BUMPER .

2007 BMW 335i
Fit protective caps.
Fig. 6: Bumper, Template And Removal Direction

Place drilling hole template (1) on radiator grille (2) and bumper (3).
NOTE: Hole diameter = 2.5 mm (see template).
Drill holes according to number/license plate.
Remove template (1) and secure number/license plate with screws provided.
Fit protective caps.
Fig. 7: Drilling Hole Template, Radiator Grille, Removal Direction And Bumper
Repairing thread:
2007 BMW 335i
Drill out defective hole in bumper (2) to 9.5 mm diameter.
Insert blind rivet nut (1).
Secure number/license plate (3) with number/license plate screw (4).
Fig. 8: Bumper, Blind Rivet Nut, Number/License Plate Screw And Number/License Plate
51 11... REMOVING AND INSTALLING/REPLACING COVER FOR HEADLIGHT WASHER

SYSTEM ON LEFT
 00 9 340
Cover for headlight washer system is spring-mounted. Pulling out the cover
too quickly or with excessive force may cause the springs to be over-
elongated.
If the springs are over-elongated, the cover for the headlight washer system
may rattle on the bumper.
Lever out cover (1) with special tool 00 9 340 .

2007 BMW 335i
Fig. 9: Cover And Special Tool 00 9 340

Slowly pull out spray nozzle (1) from cover (2) until nozzle (1) can be gripped with pliers (3), grip nozzle (1) by
rib and pull out.
Release catches (4) and remove cover (2).
Allow nozzle (1) to slide back slowly.
Installation:
To pull out nozzle (1), position pliers (3) on rib only (see Fig. 10).
Fig. 10: Spray Nozzle, Cover, Pliers And Catches

Installation:
Springs (1) must not be over-elongated.
Catches (2) must not be damaged

2007 BMW 335i
Fig. 11: Springs And Catches

51 11 050 REMOVING AND INSTALLING/REPLACING SUPPORT FOR FRONT BUMPER PANEL
IMPORTANT: During replacement, all the cavities of the carrier (1) and the crashbox (2) must
be sealed with cavity sealant.
Fig. 12: Carrier And Crashbox

 Remove front Bumper Trim

 Remove fanfare horn on Left /Right
Release screw (1) on cooling air guide (2) on left and right.
Depending on engine version, release screws in area (A).
Remove cooling air guide (2) on left and right.

2007 BMW 335i
NOTE: The following work step ends here:
"Removing and installing cooling air guide".
Fig. 13: Screw, Cooling Air Guide And Screw Area

Release screw (1).
Release nuts (2) and blind rivets (3).
Installation:
Blind rivets (3) are not refitted.
If necessary, feed out cable and remove carrier (4).
Fig. 14: Blind Rivets, Carrier, Mounting Screw And Nuts

2007 BMW 335i
51 11 055 REMOVING AND INSTALLING/REPLACING SUPPORT FOR FRONT BOTTOM

BUMPER PANEL
 Remove front BUMPER PANEL
Remove impact absorber (1).
Mark top side on support (3).
Release screws (2) and remove support (3).
Installation note:
Install support (3) with marked side towards top.
Fig. 15: Removing Support For Front Bottom Bumper Panel

51 11 156 REMOVING AND INSTALLING FRONT BUMPER TRIM
Version with headlight washer system:
 Remove Cover For Headlight Washer System on left/right
Release screws (1) on bumper trim (2).

2007 BMW 335i
Fig. 16: Retaining Screws And Bumper Trim

Release screws (1) on wheel arch trim (2) on left and right.
Lift out wheel arch trim (2) at side.
Installation:
Make sure wheel arch trim (2) is in correct position.
Fig. 17: Screws And Wheel Arch Trim

Press wheel arch cover (1) to one side.
Release left and right screws (2).

2007 BMW 335i
Fig. 18: Wheel Arch Cover And Retaining Screws

Fig. 19: Screws And Bumper Trim

IMPORTANT: Do not damage bumper trim when pulling off.
Detach bumper trim (1) at sides.
Pull bumper trim (1) forwards slightly and if necessary disconnect plug connections on ultrasonic sensors
and/or fog lights.
Remove bumper trim (1) towards front with aid of a 2nd person.
Installation:
Height adjustment, refer to 41 00... GAP DIMENSIONS , body.

2007 BMW 335i
Fig. 20: Bumper Trim And Removal Directions

51 11 157 REPLACING FRONT BUMPER TRIM
 Remove front Bumper Trim

 Remove Front Grille Centre Section
 Remove License Plate Holder
 Remove Middle Grille
 Remove Side Grille
 Remove cover cap for tow lug
Version with fog lamps:
 Remove Fog Lamps
Version with Park Distance Control (PDC):
 Remove Ultrasonic Transducer
Remove seal (1) towards top.

2007 BMW 335i
Fig. 21: Seal And Removal Direction

Detach sheet metal nuts (1) on right/left.
Version without fog lamps:
Release screws (2) and remove cover (3).
Remove sheet metal nuts on right/left below cover (3).
Fig. 22: Sheet Metal Nuts, Screws And Cover

E90/E91 only:
Press down catches (1) an insert (2) and remove insert (2) in direction of arrow.
2007 BMW 335i
Fig. 23: Insert, Catches And Removal Direction

E92/E93 only:
Press down catches (2) on insert (1) and remove insert (1) in direction of arrow.
Fig. 24: Catches And Insert

Version with M Technic aerodynamic kit:
Release expander rivets (1) and remove lip (2).

2007 BMW 335i
Fig. 25: Rivets And Lip

51 11 158 REPLACING BASEPLATE FOR LICENSE PLATE
Release screws or rivets (1).
Remove license plate baseplate (2).
Fig. 26: Rivets And License Plate Baseplate

51 11 180 REMOVING AND INSTALLING / REPLACING CENTER GRILLE FOR BUMPER TRIM
Version with ACC:
 Remove Cover For ACC sensor
Release catches (1) on bumper trim (2).

2007 BMW 335i
Installation:
Catches (1) on bumper trim (2) must not be damaged.
Fig. 27: Catches And Bumper Trim

51 11 185 REMOVING AND INSTALLING / REPLACING SIDE GRILLE FOR BUMPER TRIM
right side.
Release catches (1) on bumper trim (2).
Installation:
Catches (1) on bumper trim (2) must not be damaged.

2007 BMW 335i
Fig. 28: Catches And Bumper Trim

51 11 773 REPLACING FRONT LOWER LEFT OR RIGHT DEFORMATION ELEMENT
 Remove support for bumper panel at front bottom.

 Remove FRONT UNDERBODY PROTECTION.
 Remove brake air duct.
Release screw (1).
Remove deformation element (3).
Fig. 29: Removing Deformation Element

REAR BUMPER
51 12.. OVERVIEW OF REAR BUMPER
2007 BMW 335i
Fig. 30: Identifying Rear Bumper Components

51 12 050 REMOVING AND INSTALLING/REPLACING CARRIER FOR REAR BUMPER TRIM
IMPORTANT: During replacement, all the cavities of the carrier (1) and the crashbox (2) must
be sealed with cavity sealant.
2007 BMW 335i
Fig. 31: Carrier And Crashbox

 Remove Bumper Trim
If necessary, release screws (1) and feed out suspension (2) from rear muffler.
Unscrew nuts (3).
Remove carrier (4).
For tightening torque refer to 51 12 1AZ .
Fig. 32: Suspension, Nuts, Screws And Carrier

Replacement:
If necessary, release rubber mount (1) on carrier (2).

2007 BMW 335i
Fig. 33: Rubber Mount And Carrier

51 12 090 REMOVING AND INSTALLING/REPLACING TRIM GRILLE IN BUMPER TRIM
 Remove rear BUMPER TRIM
Release catches (1) and remove center grille (2).
Installation:
Fig. 34: Identifying Centre Grille And Catches

51 12 156 REMOVING AND INSTALLING REAR BUMPER TRIM
 Remove left/right Rear Light

2007 BMW 335i
Lever out cover (1) and release screw underneath.
Fig. 35: Rear Bumper Trim Cover

Release screw (1) on left/right.
Bend wheel arch trim (2) in area (A) to one side and release screw (3) on left/right.
Fig. 36: Wheel Arch Trim, Screws And Retaining Area

Release screws (1 to 3).

2007 BMW 335i
Fig. 37: Rear Bumper Trim Retaining Screws

IMPORTANT: Risk of damage
Do not detach bumper trim (1) at sides
The following work must be carried out with a second person assisting:
Pull bumper trim (1) towards rear and release from catches (2).
Fig. 38: Rear Bumper Trim, Catches And Removal Direction

Press down catch (2).
Remove bumper trim (1) towards rear with aid of a 2nd person.
If necessary, disconnect plug connection on ultrasonic transducers.

2007 BMW 335i
Fig. 39: Catch And Bumper Trim

51 12 157 REPLACING REAR BUMPER TRIM
 Remove rear Bumper Trim
 Remove trim from bumper

 Remove bottom middle trim
Remove cover cap (1) for tow lug.
Version with PDC:
Remove all Ultrasonic Transducers (2).
Fig. 40: Cover Cap And Ultrasonic Transducers

2007 BMW 335i
51 12 801 REMOVING AND INSTALLING/REPLACING HOLDER FOR REAR LEFT OR RIGHT

BUMPER
Operation is described in: Replacing Both Holders For Bumper At Rear.
51 12 821 REPLACING BOTH HOLDERS FOR REAR BUMPER
 Remove Rear Bumper Trim
right side.
E93 only:
Release antenna holders (1 and 2) from holder (3).
Installation:
If necessary, replace faulty antenna holders (1 and 2).
Fig. 41: Antenna Holders And Holder

If necessary, disconnect plug connection at trigger transmitter.
Release nut (3) and remove holder (4).

2007 BMW 335i
Fig. 42: Holder, Screws And Nuts

Installation:
Catches (1) must not be damaged or missing.
E90/E91 only:
Replacement:
If necessary, remove RDC Trigger Transmitter .
Fig. 43: Rear Bumper Holder Catches

51 12 825 REMOVING AND INSTALLING/REPLACING GUIDE FOR REAR CENTER BUMPER
 Remove rear Bumper Trim

2007 BMW 335i
Version with Comfort Access:
 Remove Bumper Aerial For Comfort Access
E93:
 Release bumper antenna from bumper guide
If necessary, feed out cable (1) of Park Distance Control.
Release nuts (2) and remove guide (3).
Fig. 44: Park Distance Control Cable, Nuts And Guide

71 60... REPLACING COMPLETE TRAILER TOW HITCH
See REPLACING COMPLETE TRAILER TOW HITCH .
TRIM, COVERS, HANDLE TRIM

51 13 047 REMOVING AND INSTALLING (REPLACING) GRILLE ON SIDE PANEL AT FRONT
LEFT OR RIGHT
WARNING: Follow. See INSTRUCTIONS FOR HANDLING LIGHT BULBS (EXTERIOR

LIGHTS) .
Unlock catches (1) under side panel grille (2) with special tool 64 1 020 .
Unclip side panel grille (2) in direction of arrow from front side panel (3) and remove against direction of
travel.

2007 BMW 335i
Installation:
Make sure side panel grille (2) is correctly seated on front side panel (3).
Fig. 45: Unlocking Catches Under Side Panel Grille With Special Tool
Installation:
Catches (1) on side panel grille (2) must not be damaged.
Fig. 46: Identifying Catches And Side Panel Grille

51 13 017 REMOVING AND INSTALLING/REPLACING FRAME FOR GRILLE IN ENGINE

HOOD/BONNET ON LEFT OR RIGHT
Lever out frame (1) with special tool 00 9 323 (scraper) along dashed line.
Carefully pull frame (1) in direction of arrow out of guide and remove.
2007 BMW 335i
Installation:
Make sure frame (1) is correctly seated in respective locators.
Fig. 47: Identifying Frame

Installation:
Catches (1) and guides (2) must not be damaged.
Fig. 48: Identifying Catches And Guides

51 13 001 REMOVING AND INSTALLING/REPLACING FRONT RADIATOR GRILLE, MIDDLE

LEFT OR RIGHT
Release screws (1) and pull bumper trim (3) forwards slightly.
Release catches (4) from inside and remove central radiator grille (2) towards front.
2007 BMW 335i
Fig. 49: Central Radiator Grille, Screws, Catches, Bumper Trim And Removal Direction
Installation:
All catches and guides on middle front grille must not be damaged.
Press on chrome ring to push front radiator grille (2) in to bumper trim.
Fixtures (1) must engage correctly.
Fig. 50: Front Radiator Grille, Fixtures And Installation Direction

Replacement:
Release catches (1).
Remove chrome frame (2) from radiator grille (3).
Installation:
Catches (1) on chrome frame (2) and radiator grille (3) must not be damaged.
2007 BMW 335i
Fig. 51: Catches, Chrome Frame And Radiator Grille

51 13 116 REMOVING AND INSTALLING COWL PANEL COVER
 Remove Windscreen Wiper Arm on left/right

 Remove Microfilter Housing
IMPORTANT: Danger of water ingress via fan into vehicle interior if cowl panel cover and
sealing strip are not correctly fitted.
Pull off hose (1).
Detach mucket (3).
Take off cover (4).
Installation:
Make sure cover (4) is correctly seated.

2007 BMW 335i
Fig. 52: Plug Connections, Hose, Mucket And Cover

Installation:
Sealing strip (1) must be fitted (water ingress)
If necessary, retrofit sealing strip (1).
Fig. 53: Cowl Panel Cover Sealing Strip

Installation:
Make sure grommets (1) are correctly seated on wiper pivots.
Grommets (1) for wiper pivots must not be damaged.
If necessary, replace grommets (1).

2007 BMW 335i
Fig. 54: Wiper Pivot Grommets

E90/E91 only:
Installation:
Cowl panel cover (1) must be correctly guided on right and left under windscreen cover (2).
Fig. 55: Cowl Panel Cover And Windscreen Cover (E90/E91 Only)
E92/E93 only:
Installation:
Cowl panel cover (1) must be correctly guided on right and left under windscreen cover (2).
2007 BMW 335i
Fig. 56: Cowl Panel Cover And Windscreen Cover (E92/E93 Only)
51 13 117 REPLACING COWL PANEL COVER
 Remove Cover For Cowl Panel

 Remove Spray Nozzle on left/right
Release catches on grommets (1) and remove grommets (1) in outwards direction.
Release holder (2).
Remove washer fluid hose (3) and if necessary cable.
Installation:
Grommets (1) for wiper pivots must not be damaged; if necessary, replace grommets (1).
Fig. 57: Grommets, Holder And Washer Fluid Hose

2007 BMW 335i
51 13 280 REMOVING AND INSTALLING/REPLACING TRIM STRIP ON ROOF FRAME AT LEFT

OR RIGHT
 00 9 321
E91 only:
 If necessary, remove roof rails
Lever out trim strip (1) with special tool 00 9 321 starting at rear.
Unclip trim strip (1) in direction of arrow.
Fig. 58: Special Tool (00 9 321), Trim Strip And Removal Direction
Installation:
Clips (1) and seals (2) on trim strip (3) must not be damaged.
If necessary, replace faulty clips (1).
Position of clips (1) on trim strip (3) is determined by notch (4).

2007 BMW 335i
Fig. 59: Clips, Seals, Trim Strip And Notch

Installation:
Push trim strip (1) at front into seal (2).
Trim strip (1) must be flush with edge (3) at rear.
Fig. 60: Trim Strip, Edge And Seal

51 13 286 REPLACING BRACKET FOR ROOF LUGGAGE RACK ON LEFT OR RIGHT
 Remove TRIM STRIP FROM ROOF FRAME
Remove body sealing compound (1) with special tool 00 9 322 (wedge) and unfasten threaded pin (2).
2007 BMW 335i
Fig. 61: Identifying Body Sealing Compound And Threaded Pin

NOTE: Threaded pin is designed as Torx from E87 model series.
Installation:
Threaded pin may not be wetted with screw securing adhesive on screw-in thread (1).
Before installing threaded pin, protect body against corrosion (e.g. apply zinc dust paint).
Fig. 62: Identifying Screw-In Thread

Apply body sealing compound (1) (Terostat 9320, sourcing reference: BMW Parts Service) to threaded pin (2)
all round.
After hardening time of body sealing compound (1), paint over body sealing compound (1) and threaded pin (2)
with paint pencil of corresponding car color.
2007 BMW 335i
Fig. 63: Identifying Body Sealing Compound And Threaded Pin

51 13 312 REMOVING AND INSTALLING/REPLACING TRIM STRIP ON ROOF GUTTER AT

LEFT OR RIGHT
 Remove Rear window cavity weather Strip
IMPORTANT: Make sure that body is not damaged.
Carry out work with a second person assisting.
Start at front, pull off trim strip (1) in direction of arrow from clips (2).
Installation:
To avoid leaks and noises, check all clips (2) for visible damage.
Fig. 64: Trim Strip, Clips And Removal Direction

2007 BMW 335i
Installation:
Make sure seals (1 and 2) are correctly seated on trim strip (3).
Replacement:
Moisten seals (1 and 2) and trim strip (3) with water.
Slide seals (1 and 2) into trim strip (3).
Fig. 65: Seals And Trim Strip

IMPORTANT:  Carry trim strip by its middle section only (risk of damage)
 Perform installation work with a second person helping
 Prepositioning of trim strip
 Ensure drip molding runs parallel to side frame (risk of breakage)
51 13 316 REMOVING AND INSTALLING OR REPLACING TRIM STRIP ON ROOF GUTTER AT

LEFT OR RIGHT (CONVERTIBLE)
Detach mucket (1) in area of trim strip (3).
Pull seal (2) out of trim strip (3).
Release screws (4).
Tightening torque: 1, 8 Nm.

2007 BMW 335i
Fig. 66: Identifying Mucket, Seal, Trim Strip, And Screws

Carefully feed trim strip (1) out of mucket (2) and remove.
Fig. 67: Identifying Feed Trim Strip And Mucket

Installation:
Sealing tape on trim strip (1) and trim strip (1) must not be damaged.
Contact surfaces of trim strip (1) must be clean.
Installation sequence:
 Feed trim strip (1) into mucket in area (A).

 Secure trim strip (1) with screws loose.
 Insert rubber seal (2).
 Screw down trim strip (1).
2007 BMW 335i
Fig. 68: Identifying Area For Feeding Trim Strip Into Mucket
Installation:
To facilitate installation, moisten seal (3) with water.
Feed seal (3) in, first over edge (A), then over edge (B) of trim strip (1).
NOTE: Always make sure seal (3) is correctly fitted, in particular in the area of the trim
strip screw-fastening points (2).
Fig. 69: Identifying Trim Strip, Seal, And Screw Fastening Points
BMW EMBLEMS, MODEL EMBLEMS

51 14... INSTRUCTIONS FOR ATTACHING NUMBER/LETTER DESIGNATION COMBINATION
NOTE: The model designation is attached with adhesive and cannot be re-used.
2007 BMW 335i
The model designation must be attached at room temperature.
The model designation must be removed at stove-enameling temperatures

exceeding 80 °C.
NOTE: The following work steps are described using the "316 i" as the example.
Removing:
Coat nylon string or strong yarn with tensides (e.g. washing-up liquid).
Cut through adhesive layer and remove model designation (1) from rear lid (2).
Remove remainder of adhesive layer with adhesive remover.
Fig. 70: Model Designation And Rear Lid

Assembly:
Number and letter combinations (1) of the model designation are not connected to each other and are supplied
on a carrier film (2).
IMPORTANT: Adhesive areas must be dry and free of dust and grease.
Once it has been cleaned, do not touch the adhesive area with bare hands.
Remove liner (3) (protective strip for adhesive surface).
Press on model designation firmly.
Remove carrier film (2).

2007 BMW 335i
Fig. 71: Liner, Carrier Film, Number And Letter Combinations

51 14...GENERAL NOTES FOR LABELLING WITH ADHESIVE FILMS
In the event of a repair the adhesive films must be partially or completely replaced. The basic procedure for all
areas of the vehicle is described below.
In addition, vehicle-specific repair instructions are available.
1. Preparation:
Wash and dry vehicle. Rework with compressed air as required in area of joints.
Clean complete component surface with glass cleaner (BMW part number 83 12 0 396 775). Also clean the
inside of the component in areas, in which adhesive films are applied.
Only carry out repair work with clean hands!
IMPORTANT: Labels can only be applied to recently painted components after a waiting
period of 2 weeks. The paint hardening is only fully completed after this time.
2. Procedure for applying labels:
All adhesive films in the repair kit are marked with numbers. Prepare the required plastic films prior to start of
repairs.
The templates included in the repair kit assist orientation. A straight line running over the different components
is the top priority.
Pull off the templates positioning of the adhesive films.
Only throw away templates after completion of all repair work, as some templates are used several times.
Templates are always applied along the light edge (1). The light edge is the reflection of the light source in
2007 BMW 335i
radius (see arrow).
Fig. 72: Identifying Light Edge

Roughly align the adhesive film using a template.
For large adhesive films, pull off the first 20 cm of protective film and fold back the edge.
Align and lightly press down the adhesive film. Use only one finger for this and not the entire hand so that air
pockets are unable to form under the adhesive film.
Pull off the remaining protective film and press down the adhesive film from front to rear and from inside to
outside.
If faults are made in applying the adhesive film, it can be pulled off and repositioned several times. When no
further corrections have to be made, use a squeegee to press down the adhesive film firmly from inside to
outside.
Lay protruding ends of the adhesive film around the component edge and press down firmly.
Carefully pull off backing film (1) at an acute angle.

2007 BMW 335i
Fig. 73: Pulling Off Backing Film

51 14 000 REMOVING AND INSTALLING/REPLACING FRONT BMW BADGE
 00 9 318
Lever out badge with special tool 00 9 318 and remove towards top.
2007 BMW 335i
Fig. 74: Special Tool (00 9 318)

Installation:
Following parts must not be damaged or missing:
1 Badge
2 Guide pins
3 Grommets
Fig. 75: Badge, Guide Pins And Grommets

51 14 011 REPLACING REAR BMW BADGE
 00 9 323
2007 BMW 335i
IMPORTANT: The Instructions on component cementing with double-sided adhesive tape

serve as the basis for this repair instruction and must be observed without fail.
The BMW badge must be replaced after it is removed.
Removing badge:
Heat BMW badge (1) with hot air blower and carefully lever out with special tool 00 9 323 .
Fig. 76: BMW Badge And Special Tool (00 9 323)

Fitting badge:
Installation:
Grommets (1) must not be damaged.
Pull liner* off adhesive tape (2), position badge over guide pins (3) and press down firmly.
* Liner is the protective film on a new badge.

2007 BMW 335i
Fig. 77: Grommets, Adhesive Tape And Guide Pins

51 14 110 REMOVING AND INSTALLING/REPLACING REAR MODEL DESIGNATION
IMPORTANT: The "instructions For Number/Letter Combination Cementing" serve as the

basis for these repair instructions and must be followed without fail.
Fitting dimensions (E90/E91/E92/E93):
Fig. 78: [Rear Model Designation Fitting Dimensions (E90/E91/E92/E93)]

Attach adhesive tape (1) between edge of rear lid (2) and top edge "A". Mark out measurement "B" from top
edge "A" to outer edge of rear lid on adhesive tape (1).
DIMENSIONS
E90 A = 25.2 mm B = 49.3 mm
E91 A = 26.6 mm B = 65.1 mm
E92 A = 21 mm B = 49.6 mm
E93 A = 20 mm B = 52.7 mm
NOTE: Measurements C, D and E are for information purposes only, as determined by

carrier film.
2007 BMW 335i
316 i, 318 i, 318 d: C = 4.8 mm, D = 7.2 mm, E = 11.6 mm
320i...335i: C = 7.2 mm, D = 7.2 mm, E = 11.6 mm
320 d...330 d: C = 7.2 mm, D = 7.2 mm, E = 11.6 mm
320 si, 325 xi, 330 xi, 330 xd: C = 7.2 mm, D = 7.2 mm, E = 10.6 mm, F = 4.8 mm
MIRRORS, COVERS, ASHTRAY, SHELVES, TRAYS

51 16... CALIBRATING COMPASS IN INSIDE MIRROR (UP TO 09/08)
NOTE: It may be necessary to alter the magnetic deflection zone if the vehicle is more
than two ranges away from the set deflection zone.
For numbers of magnetic deflection zone, refer to Owner's Handbook.
If may be necessary to calibrate the compass if:
 vehicle battery has been clamped off for an extended period of time
 "C" appears in compass display
 there is no compass display
Setting magnetic deflection zone:
 Switch on ignition.
 Using a suitable tool (1), press push-button in area (A) of mirror (2) until a number appears in compass
display (B)
 Press push-button repeatedly until number of desired zone appears
 Wait until direction display appears
 Magnetic deflection zone is now set
Fig. 79: Pressing Inside Mirror Push Buttons To Adjust Magnetic Deflection Zone
2007 BMW 335i
Calibrating compass:
 Switch on ignition.
 Using a suitable tool (1), press push-button in area (A) of mirror (2) until "C" appears in compass display
(B)
 Drive vehicle 2 to 3 times in a circle at approx. 10 mph
 Calibration process is completed when direction display appears
Fig. 80: Pressing Inside Mirror Push Buttons To Calibrate Compass

51 16... CALIBRATING COMPASS IN INTERIOR REARVIEW MIRROR (FROM 09/08)
NOTE: It may be necessary to alter the magnetic deflection zone if the vehicle is more
than two ranges away from the set deflection zone.
For numbers of magnetic deflection zone, refer to Owner's Handbook.
If may be necessary to calibrate the compass if:
 vehicle battery has been clamped off for an extended period of time
 "C" appears in compass display
 there is no compass display
Adjusting magnetic field zone:
 Press and hold down control button (A) on inside mirror (2) with a suitable tool (1) for 3- 6 seconds. The
currently set magnetic field zone is indicated in the compass display (B) (default setting "8" for Central
Europe). Release control button (A) briefly and select magnetic field zone (1-15) by pressing control
button (A) again. Release setting button (A) when the desired magnetic field zone is selected. The
selection menu is automatically exited after approx. 5 seconds.
 The compass must be recalibrated after the magnetic field zone has been changed.
2007 BMW 335i
Fig. 81: Pressing Interior Rearview Mirror Control Button To Adjust Magnetic Field Zone
Calibrating compass:
 Press and hold down setting button (A) on interior mirror (2) for 6-9 seconds. Release setting button (A)
as soon as "C" is indicated in the compass display (B).
 Drive vehicle 2 to 3 times in a full circle at approx. 7- 10 km/h. The circle must be at least twice the
vehicle's turning circle. Calibration is complete as soon as a valid direction is displayed.
 For convertibles and vehicles with hardtops only:
The digital compass must be calibrated once with the soft top or hardtop closed and once with the soft top or
hardtop open.
Fig. 82: Pressing Interior Rearview Mirror Setting Button To Calibrate Compass
Setting right-hand drive or left-hand drive vehicle:
 Press and hold down control button (A) on inside mirror (2) for 9-12 seconds. The currently set vehicle
2007 BMW 335i
type is indicated in the compass display (B) (default setting "L" for left-hand drive). Release setting
button (A) briefly and select vehicle ("L" or "R") by pressing setting button (A) again. Release setting
button (A) when the desired vehicle type is selected. The selection menu is automatically exited after
approx. 5 seconds.
Fig. 83: Pressing Interior Rearview Mirror Control Button To Set Right/Left Hand Drive
Setting language of compass display:
 Press and hold down control button (A) on inside mirror (2) for 12-15 seconds. The currently set language
is indicated in the compass display (B) (default setting "E" for English). Release setting button (A) briefly
and select language (E for English or O for German) by pressing setting button (A) again. Release setting
button (A) when the desired language is selected. The selection menu is automatically exited after approx.
5 seconds.
Fig. 84: Pressing Interior Rearview Mirror Control Button To Set Compass Display Language
2007 BMW 335i
51 16 992 DISASSEMBLING AND ASSEMBLING LOCK CYLINDER (LOCK CYLINDER

REMOVED)
If necessary, remove LOCK CYLINDER
NOTE:  Lock cylinder repair kit (part number: 9 061 387) applicable to:
E30
 Lock cylinder repair kit (part number: 9 061 388) applicable to:
E31, E32, E34, E36, E38, E39
 Lock cylinder repair kit (part number: 7 001 461) applicable to:
E46, E52, E53, E60, E61, E63, E64, E65, E66, E67, E85, E86, E90, E91, E92,
E93
Sort supplied retainers (1) by stamped numerical sequence (X) in ascending order and number (Y).
Fig. 85: Identifying Retainers In Numerical Sequence

Insert spring (1) into first lock cylinder position (2).
NOTE: Lock cylinder version (2) differs from vehicle to vehicle.

2007 BMW 335i
Fig. 86: Identifying Spring Into First Lock Cylinder Position

Insert retainer (1) with lowest number (X) of first position (Y) in lock cylinder (2) and snap audibly into place.
NOTE: Number of retainers (1) differs from vehicle to vehicle.
Fig. 87: Identifying Retainer And Lock Cylinder

Insert ignition key (1) into lock cylinder (3) and check whether retainer (2) is flush with housing.
 (A) OK
 (B) not OK
2007 BMW 335i
Fig. 88: Checking Retainer Flush

If retainer (2) is not OK, press retainer (2) out of lock cylinder (3) with a suitable tool (1).
Continue with next number (X) higher of first position (Y) until retainer is OK.
The continue with all the other positions in accordance with the above-mentioned procedure.
Fig. 89: Pressing Retainer Out Of Lock Cylinder Using Suitable Tool
51 16... GLUING OF MIRROR BASE
Material Requirements:
Repair set for gluing of mirror base
Primer XW 775
1. Preparation
2007 BMW 335i
1.1 Glue at room temperature and make sure that, in cold weather, the window glass and base are
brought to room temperature in the workshop long enough to prevent moisture forming on the
surface.
1.2 Mark location of the mirror mount on the outside of the windshield.
Scratch off glue residue on glass and base with a sharp tool.
1.3 Clean glue area on window and base with clean non-fluffing cloth and alcohol/acetone and
allow to dry!
Never use paint thinners!
2. Primer coat
Apply colorless, diluted primer to surface of windshield intended for gluing with help of cotton buds (Q-
Tips or similar).
Specified ventilation time at least 1 minutes, maximum 1 hour
3. Gluing coat
3.1 Mixing Glue
Cut off sealing tips on containers of glue and hardener using a knife.
Make sure that both openings are equal in size, as otherwise there would be mistakes in mixing.
The sealing cap for subsequent plugging of the double injector is located between both pistons of
the injector. Break off sealing cap.
The required amount of glue and hardener is removed by applying light pressure on the pistons.
The mixture ratio of adhesive and hardener is 1 : 1 (weight and volume). It is important that the
same volumes of glue and hardener are removed (increase size of openings if necessary).
Both components react chemically with each other. Thorough, intensive and homogenous mixing is
a requirement for this reaction and for the quality of gluing.
Consequently both components must be mixed in such a way that there is a uniform, ream-free
color mixture.
3.2 Application
At 20... 25°C the mix can be processed after approx. 5... 10 minutes (pot time).
Apply thin (approx. 0.5 mm), uniform coat of glue on base with spatula and press base onto glass in
such a way that glue obtains good contact with windshield across the entire surface area.
2007 BMW 335i
NOTE: The temperature for the hardening process should not be lower than
+18 °C.
3.3 Fixing Bonded Parts
Epoxy resin glue does not have an initial strength property. It is therefore necessary to fix all
bonded parts (adhesive tape or similar). The joining and fixing of bonded parts must be
accomplished within the potlife). Check that the arresting button is located correctly on the mirror
base to ensure that the mirror, when it is attached, is seated straight.
(Long side of mirror base hexagon parallel to upper edge of window).
3.4 Hardening of glue
Hardening speed depends on the ambient temperature.
For this reason, the mirror base must be secured with adhesive tape or similar for at least 3... 4
hours.
After 12 hours have elapsed, clip mirror into place as soon as possible.
4. Working hygiene
IMPORTANT: Glue is dangerous for health when vapors are inhaled or through contact
with the skin.
As is the case for all epoxy resins, sensitive persons might be confronted with an allergy through contact
with the skin.
If the product gets on the skin, wash off with soap and water immediately.
If it gets in an eye, rinse the eye thoroughly in water and consult doctor.
Make sure that the room is well ventilated and gloves are worn for the application of glue.
51 45... OVERVIEW OF INSTRUMENT PANEL

2007 BMW 335i
Fig. 90: Overview Of Instrument Panel

51 16... OVERVIEW OF REAR CONSOLE

2007 BMW 335i
Fig. 91: Identifying Rear Console Components

51 16... OVERVIEW OF STORAGE COMPARTMENT (CENTER CONSOLE)

2007 BMW 335i
Fig. 92: Identifying Storage Compartment Components (Centre Console)

51 16 000 REMOVING AND INSTALLING/REPLACING MIRROR ON LEFT OR RIGHT FRONT

DOOR
Unclip trim (1) from retaining clip (2) in inward direction.
Slide trim (1) upwards slightly out of guide (3) and remove.
NOTE: On version with speaker, trim (1) can remain hanging over door trim panel.
Installation:
Retaining clip (2) must be fitted on door.

2007 BMW 335i
Fig. 93: Trim, Retaining Clip, Guide And Removal Directions

Installation:
Following parts of trim must not be damaged or missing:
1. Sound insulation
2. Retaining lug
3. Guide
Fig. 94: Sound Insulation, Retaining Lug And Guide

IMPORTANT: Secure door mirror against falling down.
Fold seal (2) to one side slightly and release screws (3).
For tightening torque refer to 51 16 1AZ .

2007 BMW 335i
Installation:
Rubber grommet for plug connection (1) must be correctly seated on door.
Seal (2) must be correctly seated on door trim panel and door.
Fig. 95: Plug Connection, Screws And Seal

Remove mirror (1) outwards.
Installation:
Check function.
Fig. 96: Mirror And Removal Direction

Replacement:
 Modify Mirror Glass, replace if necessary

 Modify Cover Cap, replace if necessary
2007 BMW 335i
51 16 026 REPLACING MIRROR GLASS
 00 9 317
WARNING: Move mirror glass with hand carefully and slowly.
If mirror glass is damaged:
Wear protective goggles and cut-proof gloves.
Risk of injury by flaking-off glass splinters.
IMPORTANT: Bring door mirror to room temperature to prevent catches from breaking off.
Press mirror glass (1) on side vehicle by hand to full extent.
NOTE: Secure mirror glass (1) against falling out.
Unclip mirror glass (1) from outer side with special tool 00 9 317 all round.
Unlock and disconnect associated plug connections, remove mirror glass (1).
Fig. 97: Mirror Glass, Special Tool (00 9 317) And Removal Directions
Installation:
Retaining lugs (1) must not be damaged.
Fit mirror glass (2) with retaining lugs (1) flush on mirror adjusting drive and clip into place.
2007 BMW 335i
Ensure correct locking.
Make sure mirror adjusting drive functions correctly.
Fig. 98: Retaining Lugs And Mirror Glass

51 16 040 REMOVING AND INSTALLING/REPLACING HOUSING ON LEFT OR RIGHT DOOR

MIRROR
 Remove Mirror Glass
NOTE: Housing (2) is secured without play by four multitooth catches (1) on retaining
ring (3).
Secure housing on door mirror (2) against falling out.
Unlock multitooth catches (1) with a screwdriver.
Unclip housing (2) forwards from retaining ring (3) and remove.
2007 BMW 335i
Fig. 99: Housing, Multitooth Catches, Retaining Ring And Removal Direction
Installation:
Multitooth catches (1) and guide (2) on housing (3) must not be damaged.
Fig. 100: Catches, Guide And Housing

Installation:
Locators (1) on retaining plate (2) must not be damaged.

2007 BMW 335i
Fig. 101: Locators And Retaining Plate

51 16 045 REMOVING AND INSTALLING OR REPLACING RETAINING RING ON LEFT OR

RIGHT DOOR MIRROR
 00 9 317
 Remove Housing On Door Mirror

 Remove Drive for electrically adjustable door mirror
Release screws (1) on retaining ring (2).
Fig. 102: Screws On Retaining Ring

Starting at bottom, unclip catches (1) all round from retaining ring (2) with special tool 00 9 317 .
2007 BMW 335i
Remove retaining ring (2).
Fig. 103: Catches And Retaining Ring

Installation:
Catches (1) must not be damaged.
Locators (2) for multitooth catches must not be damaged.
Fig. 104: Catches And Locators

51 16 060 REMOVING AND INSTALLING/REPLACING INTERIOR REARVIEW MIRROR

(OVERVIEW)
NOTE: Version with cable (X) for:
 Automatic dim action (electro-chrome technology) for interior rearview

mirror
 Fogging sensor
2007 BMW 335i
 Remote control (infrared or radio)

 Autobeam
 Garage door opener
 Compass
 Rain sensor
Version without cable (X) with full foot (1).
Fig. 105: Rearview Mirror Foot

Version with cable (X) and plug trim cover (1).
Fig. 106: Rearview Mirror Plug Trim Cover

Version with mirror arm end caps (1).

2007 BMW 335i
Fig. 107: Arm End Caps Rearview Mirror

Version with rain sensor.
Fig. 108: Rain Sensor Rearview Mirror

Version with Autobeam.

2007 BMW 335i
Fig. 109: Autobeam Rearview Mirror

Version with toll mirror for Japan.
Fig. 110: Japanese Toll Rearview Mirror

51 16 060 REMOVING AND INSTALLING/REPLACING INTERIOR REARVIEW MIRROR (WITH

AUTOBEAM)
IMPORTANT: Work may only be carried out at a room/object temperature of 18... 28 °C.
If this cannot be guaranteed (cold/hot countries), it is necessary to equalize the

temperature of the windscreen, mirror foot and rearview mirror (e.g. car left to
stand indoors or in the shade for at least 30 minutes).
Version with remote control for central locking:
If necessary, disconnect negative lead from Battery .
IMPORTANT: To avoid breaking windscreen:
Snap out (press) rearview mirror only in direction of travel towards windscreen.
Do not under any circumstances twist the mirror foot when removing.
Twisting the mirror off the mirror mount will damage the rear catch.
If the rear catch is damaged, the mirror will be loose when installed and must
be replaced.
Press on end caps (1) and at same time pull them apart; this releases clip connection of both caps (1).
2007 BMW 335i
Twist mirror (2) and detach end caps (1) from mirror and feed out.
Fig. 111: End Caps, Mirror And Removal Directions

Installation:
Retaining hooks (1 and 2) of end caps (3) must not be damaged.
Fig. 112: Retaining Hooks And End Caps

Disconnect plug connections (1 and 2).
Installation:
If necessary, pay attention to cable routing for rain sensor.

2007 BMW 335i
Fig. 113: Plug Connections

Do not pull off rearview mirror (1) from windscreen against direction of travel
and or snap out by turning.
When snapping out, avoid damaging rain sensor (3).
Carefully press mirror (1) forwards out of mirror base (2).
If mirror (1) rests on rain sensor (3), snap mirror (1) out in inward direction.
Fig. 114: Mirror, Mirror Base, Rain Sensor And Removal Direction
Installation:
1. Twist mirror foot by approx. 45° and fit to mirror mount.

2. Turn mirror foot until it engages on mirror base.
2007 BMW 335i
Fig. 115: Mirror Foot Twisting Angle

NOTE: Normalization or initialization is not necessary.
Autobeam is automatically aligned under the following conditions:
 Driving on a motorway/ordinary road at night for approx. 50 km and

 Clearly visible road markings
Only replace with version with remote control for central locking:
If necessary, initialize all transmitters (ignition keys), refer to Owner's Handbook.

JAPANESE TOLL MIRROR)

Version with compass:
Check compass function if replacing or after disconnecting interior mirror plug connection or battery.
If necessary, calibrate compass in interior rearview mirror. See CALIBRATION UP TO 09/08 or

CALIBRATION FROM 09/08.
2007 BMW 335i
E60 Security version:
Rain sensor is not in stalled, cable connection is tied back in roofliner.
Screw rearview mirror off mirror mount.
Mirror must not be pulled or pressed off towards front or rear.
Press on end caps (1) and at same time pull them apart; this releases clip connection of both caps (1).
Fig. 116: End Caps And Removal Directions

Turn mirror (1) to right and left and feed out end caps (2).
Fig. 117: Mirror And End Caps

Installation:
2007 BMW 335i
Catches (1) and guides (2) of end caps (3) must not be damaged, replace if necessary.
Fig. 118: Catches, Guides And End Caps

Disconnect plugs (1 and 2).
NOTE: Pay attention to cable guide for rain sensor.
Fig. 119: Rain Sensor Plugs

IMPORTANT: Do not pull or press rearview mirror off towards front or rear.
Because of altered mirror foot, rearview mirror must be twisted off.
Twist mirror foot approx. 45° to right until mirror foot is released from mirror mount.
2007 BMW 335i
Fig. 120: Mirror Foot Twisting Angle (1 Of 2)

Installation:

Fig. 121: Mirror Foot Twisting Angle (2 Of 2)

51 16... REMOVING AND INSTALLING/REPLACING COVER CAP ON LEFT OR RIGHT DOOR

MIRROR
 Remove MIRROR GLASS.

2007 BMW 335i
NOTE: Cover cap is secured without play by four multitooth catches (1) on retaining
ring (2).
Secure cover cap against falling off.
Unlock multitooth catches (1) with a screwdriver.
Unclip cover cap forwards from retaining ring (2) and remove.
Fig. 122: Identifying Multitooth Catches And Retaining Ring

Installation:
Multitooth catches (1), catch (2) and guides (3) must not be damaged.
Fig. 123: Identifying Multitooth Catches, Catch And Guides

Installation:
2007 BMW 335i
Locators (1) on retaining ring (2) must not be damaged.
Fig. 124: Identifying Retaining Ring


MIRROR ARM END CAPS)


2007 BMW 335i
be replaced.
NOTE: Do not exert any pressure on mirror foot when removing end caps (1).
Press end caps (1) towards mirror housing (2); this releases clip connection of both caps (1).
In order not to create any tension at the mirror foot, simultaneously apply counterpressure to the mirror housing
when removing the end caps.
Fig. 125: End Caps, Mirror Housing And Removal Direction

Twist mirror (1) at an angle towards front and right/top.
Swivel left end cap (2) off ball neck in direction of arrow; this detaches the engagement clip (3) from the metal
foot.
Fig. 126: Mirror, End Cap, Engagement Clip And Removal Direction
Twist mirror (1) at an angle towards front and left/top.

2007 BMW 335i
Swivel right end cap (2) off ball neck in direction of arrow; this detaches the engagement clip from the metal
foot.
Fig. 127: Mirror, End Cap And Removal Direction

Installation:
Clips (1) and retaining hooks (2) of end caps (3) must not be damaged, replace if necessary.
Fig. 128: Clips, Retaining Hooks And End Caps

Version with cable (X):

2007 BMW 335i
Fig. 129: Plug Connection

Snap out interior mirror (1) from mirror mount (2) towards front with increasing pressure (not abruptly) and
remove.
Fig. 130: Interior Mirror, Mirror Mount And Removal Direction

Installation:

2007 BMW 335i

Initialize all transmitters (ignition keys), refer to Owner's Handbook.

RAIN SENSOR)


2007 BMW 335i
be replaced.
Press on end caps (1) and at same time press them apart; this releases clip connection of both caps (1).
Fig. 132: End Caps And Removal Directions

Twist mirror (1) at an angle towards front and right/top.
Swivel left end cap (2) off ball neck in direction of arrow; this detaches the engagement clip (3) from the metal
foot.
Fig. 133: Mirror, End Cap, Engagement Clip And Removal Direction
Twist mirror (1) at an angle towards front and left/top.

2007 BMW 335i
Swivel right end cap (2) off ball neck in direction of arrow; this detaches the engagement clip from the metal
foot.
Fig. 134: Mirror, Right End Cap And Removal Direction

Installation:
Clips (1) and retaining hooks (2) of end caps (3) must not be damaged, replace if necessary.
Fig. 135: Clips, Retaining Hooks And End Caps

NOTE: Pay attention to cable guide (2) for rain sensor.

2007 BMW 335i
Fig. 136: Plug Connection And Cable Guide

When snapping out, do not damage control unit (3) for rain sensor.
Rain sensor is not in stalled.
Snap out interior mirror (1) from mirror mount (2) towards front with increasing pressure (not abruptly) and
remove.
Fig. 137: Interior Mirror, Mirror Mount, Control Unit And Removal Direction
Installation:
2007 BMW 335i


51 16 080 REMOVING AND INSTALLING OR REPLACING SUN VISOR AND LEFT OR RIGHT
COUNTER-SUPPORT (COUPE)
NOTE: The operation is shown on the left side; proceed in the same way for the right
side.
Fold down sun visor (5).
Lever out trim (2) on counter support (1) and release screw underneath.
Release screws (3) on holder (4).

2007 BMW 335i
Fig. 139: Sun Visor, Trim, Counter Support, Screws, Holder And Removal Direction
Lift out sun visor (1).
If necessary, pull out cable (2) slightly and disconnect plug connection (3).
Installation:
Perform function check on lighting.
Fig. 140: Sun Visor, Cable And Plug Connection

51 16 080 REMOVING AND INSTALLING OR REPLACING SUN VISOR AND LEFT OR RIGHT
COUNTER-SUPPORT (CONVERTIBLE)
Lever sun visor (1) out of counter-support (2) in direction of arrow.
Release screws (3) and feed out sun visor towards bottom.
If necessary, disconnect plug connection and remove sun visor (1).
Installation:
Perform function check on lighting.

2007 BMW 335i
Fig. 141: Identifying Sun Visor Screws

Lever out side strips (1).
Release screws (2) and remove counter-support (3).
Installation:
Strips (1) must not be damaged.
Fig. 142: Identifying Counter-Support And Strips

51 16 360 REMOVING AND INSTALLING RIGHT GLOVE BOX
 Remove INSTRUMENT PANEL TRIM, bottom right
Release screws (1) and remove counter-support (2).

2007 BMW 335i
Installation:
Align glove box and screw down counter-support (2).
Check gap dimensions and closing comfort of glove box, realign if necessary.
Fig. 143: Identifying Counter Support And Screws

Release clip (1).
Remove glove box (2) in inward direction.
If necessary, disconnect plug-in contacts.
Fig. 144: Removing Glove Box

51 16 366 REMOVING AND INSTALLING RIGHT GLOVEBOX WITH HOUSING

2007 BMW 335i
Version with can holder:
 Remove both front Cup Holders
Release screws (1).
Pull out glovebox (1) slightly.
Fig. 145: Glovebox Screws And Removal Direction

Disconnect plug connections (2) and feed cable out of guide (3).
Depending on version, disconnect further plug connections.
Remove glovebox (1).
Fig. 146: Plug Connections, Glovebox And Guide

Installation:
Guides (1) for glovebox must not be damaged or missing.

2007 BMW 335i
Guides (2) for cup holders must not be damaged or missing.
Fig. 147: Identifying Guides For Glovebox And Cup Holder

51 16 366 REMOVING AND INSTALLING RIGHT GLOVE BOX (WITH AIRBAG) WITH HOUSING
WARNING: Read and comply with SAFETY REGULATIONS for handling airbag
modules and pyrotechnical belt tensioners.
IMPORTANT: Do not carry out any repairs on airbag module!
Always replace the passenger protection airbag module completely!
When working on trim panel components, make sure that the sensitive surfaces are not scratched or damaged.
 Microencapsulated screws must be replaced and may not be reused

 Screw connection must be completed within 20 minutes (start of curing)
 Microencapsulated screws must not be retightened
 Clean thread of nut beforehand in event of repeated use
 Disconnect BATTERY NEGATIVE CABLE .

 Open glove box.
 Remove both front CUP HOLDERS at the front.

2007 BMW 335i
Release screws (1).
Fig. 148: Glovebox Screws And Removal Direction

Release screws (1).
Replace micro-encapsulated screws (1).
Pull out glove box (2) slightly.
Fig. 149: Identifying Micro-Encapsulated Screws

Disconnect plug connections (1) and feed cable out of guides.
Depending on the version, disconnect additional plug connections.
Remove the glove box (2).

2007 BMW 335i
Fig. 150: Identifying Connectors

Installation note:
Guides (1) for glovebox must not be damaged or missing.
Guides (2) for cup holders must not be damaged or missing.
Fig. 151: Identifying Guides For Glovebox And Cup Holder

51 16 154 REMOVING AND INSTALLING/REPLACING INSERT FOR CENTER CONSOLE
 Remove Trim For Storage Compartment
Remove foam material (1).

2007 BMW 335i
Release screws (2) and remove insert/ashtray (3).
Fig. 152: Foam Material, screws And Insert/Ashtray

51 16 156 REPLACING ASHTRAY INSERT
Open ashtray cover (1) and pull ashtray lid (2) out of locator.
Installation:
Press ashtray insert (2) until it snaps into the locator.
Fig. 153: Ashtray Cover, Lid And Removal Direction

51 16 200 REMOVING AND INSTALLING STORAGE COMPARTMENT

2007 BMW 335i
 Remove Rear Console
Lever out covers (1) and release screws underneath.
If necessary, detach cable from storage compartment.
Fig. 154: Covers

Unscrew nuts (1).
Depending on equipment specification, disconnect plug connections (2).
Installation:
Fig. 155: Plug Connections And Nuts

Pull off gaiter (1) towards top.

2007 BMW 335i
Detach plug connection (2) from holder and disconnect plug connection (2).
Fig. 156: Gaiter, Plug Connection And Removal Direction

Raise storage compartment (2) at rear and feed out gaiter (1) through opening.
If necessary, disconnect further plug connections and feed out cable.
Remove storage compartment (2) towards rear/top.
Fig. 157: Storage Compartment, Gaiter And Removal Direction

Installation:
Guide (1) of storage compartment (2) must be fed behind panel (4) on left/right.
Version with ventilated multifunction storage:
Air duct (3) must be correctly inserted in storage compartment (2).

2007 BMW 335i
Fig. 158: Guide, Storage Compartment, Panel And Air Duct

51 16 201 REPLACING STORAGE COMPARTMENT

 Remove Centre Armrest
Version with telephone:
 Remove Eject Box
E93 only:
 Remove servodrive in storage compartment
Release catches (2) on coin holder (1) and remove coin holder (1) in inward direction.
Release catches (3) on multifunction storage compartment (4) and remove multifunction storage compartment
(4).
If necessary, remove AV connection socket (5) .
Remove socket (6).

2007 BMW 335i
Fig. 159: Catches, Coin Holder, Socket, AV Connection Socket And Multifunction Storage Compartment
Version with rear cabin air conditioning:
Release screws (1).
Lever out air duct (3) at catch (2) and feed upwards out of storage compartment.
Fig. 160: Air Duct, Screws And Catch

First feed air duct (1) to right out of guide (2) and duct (3), then remove to left out of storage compartment.
Installation:
Seal (4) must not be damaged.

2007 BMW 335i
Fig. 161: Air Duct, Seal, Guide And Duct

51 16 202 REMOVING AND INSTALLING/REPLACING FRONT (INNER OR OUTER) CUP

HOLDER
 Remove Trim On Instrument Panel on right
Release screws (1) and pull out cup holder (2) in direction of arrow.
Fig. 162: Screws, Cup Holder And Removal Direction

51 16 204 REMOVING AND INSTALLING/REPLACING REAR CUP HOLDER
Open cup holder (1) and remove mat insert (2).

2007 BMW 335i
Fig. 163: Cup Holder And Mat Insert

Lever out hinges (1).
Close lid (2) slightly and feed out completely with both hinges (1) in direction of arrow.
Repeat procedure on lid (3).
Fig. 164: Hinges, Lids And Removal Direction

Reach through openings and release catches (1).
Remove housing (2).
Installation:
Catches (1) on housing (2) must not be damaged.

2007 BMW 335i
Fig. 165: Housing And Catches

51 16 206 REMOVING AND INSTALLING / REPLACING CENTER ARMREST
 Move both front seats forwards

 Remove Rear Console
NOTE: Open center armrest otherwise spring (1) will be under too much tension.
Disengage spring (1) with screwdriver (2).
Installation:
Make sure spring (1) is correctly seated.
Fig. 166: Screwdriver, Spring And Removal Direction

Drive out hinge shafts (1).

2007 BMW 335i
NOTE: Hinge shafts (1) are secured on the outside with toothing (3).
Remove spring (2), open center armrest and feed out of storage compartment.
Fig. 167: Hinge Shafts, Spring, Toothing And Removal Directions

51 16 210 REMOVING AND INSTALLING/REPLACING TRIM FOR PRESELECTOR LEVER
 00 9 340
 Apply parking brake

 Move selector lever into N position
 Remove Gaiter for shift block
Attach special tool 00 9 340 as illustrated.
Lever out trim (1) all round.
Disconnect associated plug connections and remove trim (1) towards top.
2007 BMW 335i
Fig. 168: Trim, Special Tool (00 9 340) And Removal Directions
Installation:
Catches (1) on trim (2) must not be damaged.
Make sure catches (1) are correctly seated in associated mountings of trim (2).
Fig. 169: Catches And Trim

51 16... REMOVING AND INSTALLING/REPLACING TRIM ON LEFT OR RIGHT DOOR MIRROR
 Remove COVER CAP FROM DOOR MIRROR.
Release screws (1) and carefully remove trim (2) towards front.
Installation:
Make sure trim (2) is correctly seated on door mirror.

2007 BMW 335i
Fig. 170: Identifying Screws And Trim

Installation:
Holders (1) and guide (2) must not be damaged.
Fig. 171: Identifying Holders And Guide

51 16 284 REPLACE ONE OF THE DRINK HOLDER COVERS IN FRONT (INNER OR OUTER)
Unclip the cover (1) from the drink holder (2) direction of arrow.
2007 BMW 335i
Fig. 172: Removing Cover From Drink Holder

51 16 212 REMOVING AND INSTALLING TRIM FOR STORAGE COMPARTMENT
 00 9 317
Version with manual transmission:
 Remove Gaiter For Gear Lever
Version with automatic transmission:
 Remove Finisher For Preselector Lever
Release trim (1) with special tool 00 9 317 from retainers (2).
If necessary, disconnect plug connections and remove trim (1) towards top.
2007 BMW 335i
Fig. 173: Trim, Retainers And Special Tool (00 9 317)

Installation:
Following parts on trim (3) must not be damaged or missing:
1. Clips
2. 4 x foam material
Fig. 174: Trim, Clips And Foam Material

51 16 213 REPLACING TRIM FOR STORAGE COMPARTMENT

 Remove Insert For Centre Console
Version with controller:

2007 BMW 335i
 Remove Controller
E93 only:
 Remove switch for convertible top operation
Version without controller:
Carefully release catches (1) and remove storage tray (2).
Fig. 175: Catches And Storage Tray

51 16 260 REMOVING AND INSTALLING/REPLACING FRONT SECTION OF REAR CONSOLE

TRIM
 00 9 317
Apply special tool 00 9 317 at side and unclip trim (1) in upward direction from retaining clips (2).
If necessary, disconnect plug connections and remove trim (1).
Installation:
Clips (2) must not be damaged.

2007 BMW 335i
Fig. 176: Clips, Trim And Special Tool (00 9 317)

Replacement:
Release screws (1) and remove ashtray/oddments tray (2).
Release screws (3) and remove oddments tray/fresh-air grille (4).
Fig. 177: Screws, Ashtray/Oddments Tray And Oddments Tray/Fresh-Air Grille

51 16 265 REMOVING AND INSTALLING/REPLACING REAR SECTION OF REAR CONSOLE

TRIM
 00 9 317
E92 only:
2007 BMW 335i
 Remove Filler Element from rear seat
E93 only:
 Remove armrest for rear seat backrest
Apply special tool 00 9 317 at side and unclip trim (1) in upward direction from retaining clips (2).
Installation:
Clips (2) must not be damaged.
Fig. 178: Trim, Clips And Special Tool (00 9 317)

Replacement:
Release screws (1) and remove oddments tray (2) from trim (3).
Fig. 179: Oddments Tray, Screws And Trim

2007 BMW 335i
51 16 270 REMOVING AND INSTALLING/REPLACING REAR CONSOLE
 Remove Rear Seat on left/right

 Remove Front Section Of Rear Console Trim
 If necessary, remove Footwell Light on left/right
E93 only:
 Remove backrest for rear seat
Pull off trim (1) towards rear.
Release screws (2).
Fig. 180: Trim, Screws And Removal Direction

Installation:

2007 BMW 335i

Remove insert (1) and release nuts (2).
Fig. 182: Insert And Retaining Nuts

Release catches (1) from bottom left/right.
Release catches (2) from above with screwdriver on left/right and slide rear console (3) towards rear.
2007 BMW 335i
Fig. 183: Catches, Rear Console And Removal Direction

Slide rear console (1) towards rear until guides (2) are fed out.
Installation:
Fig. 184: Guides And Rear Console

Raise front section of rear console (1) and feed catches (2) on left/right out of storage compartment (3).
Remove rear console (1).
Replacement:
Remove Rear Console Trim At Rear .

2007 BMW 335i
Fig. 185: Rear Console, Catches, Storage Compartment And Removal Direction
51 16 340 REMOVING AND INSTALLING/REPLACING LOCK FOR RIGHT GLOVEBOX
Preliminary work needed:
 Remove the RIGHT GLOVE BOX WITH HOUSING
Unscrew the circlip (1).
Detach the piston rod (2) from the glove box damper.
Fig. 186: Identifying Piston Rod And Circlip

Unscrew the screws (2) of the glove box cover (3) and take off the mounting plates (1).
Installation note:
Do not tighten the screws (2) until after the alignment of the glove box cover (3).
2007 BMW 335i
Pull the wiring harness (4) and glove box cover (3) out of the glove box housing (5) and set them aside.
Fig. 187: Identifying Mounting Plates, Screws, Glove Box Cover, And Wiring Harness
Installation note:
First, feed the limit position (arrow) of the glove box cover (2) into the glove box housing (1).
Fig. 188: Identifying Glove Box Cover And Housing

Lever out the inner cover (1) at the front using the special tool 00 9 325.
Fold up the inner cover (1) towards the rear and pull it out.
Installation note:
Inner cover (1) must be hooked in at the rear and locked neatly at the front (see arrows).
2007 BMW 335i
Fig. 189: Removing Inner Cover

NOTE: The locking pin (1) is part of the lock replacement part supply. Alternatively, use
a 3 mm drill.
Push in the lock linkage (3) on the left and right so that the lock mechanism of the upper part lock (4) can be
retained in place using a locking pin (1) via the bore hole (2).
Fig. 190: Identifying Lock Linkage, Locking Pin, And Bore Hole
Unscrew the screws (1) of the upper part lock (2).
Fold the upper part lock (2) down forwards and disconnect the plug connection of the actuator drive (3).
Installation note:
The wiring harness (4) must not scrape against anything or be creased.
2007 BMW 335i
Fig. 191: Identifying Actuator Drive, Upper Part Lock, Wiring Harness, And Screws
Take off the upper part lock (1).
For overview:
The locking pin (2) retains the lock linkage (3) of the upper part lock (1).
Fig. 192: Identifying Locking Pin And Linkage

Pull out the wiring harnesses (1) from the lower section lock (2).
Unscrew the screws (3) of the lower section lock (2).
Pull out the lower section lock (2).
Installation note:
Feed in the lower section lock (2) at the marked location first.
2007 BMW 335i
Fig. 193: Identifying Lower Section Lock, Wiring Harness, And Screws
51 16 340 REMOVING AND INSTALLING/REPLACING LOCK FOR RIGHT GLOVEBOX (WITH

AIRBAG)
Open glovebox.
Release screws (1).
Remove lower section (3) and upper section (2) of lock.
Fig. 194: Screws, Glovebox Lock Lower Section, Glovebox Lock Upper Section And Removal Direction
Replacement:
Insert ignition key (1) in lock cylinder (3).
Turn ignition key (1) slightly, carefully raise catches (2) and pull out lock cylinder (3) with ignition key (1) in
direction of arrow.
2007 BMW 335i
If necessary, force catches (2) open.
Fig. 195: Ignition Key, Lock Cylinder, Catches And Installation Direction
51 16 342 REMOVING AND INSTALLING/REPLACING LOCK CYLINDER FOR PASSENGER

AIRBAG DEACTIVATION
Individual parts, switch for passenger airbag deactivation

2007 BMW 335i
Fig. 196: Passenger Airbag Deactivation Switch Components And Assembly Order
 Remove Switch For Passenger Airbag Deactivation
Release screws (1).
Remove housing cover (2) and PCB (3) underneath.

2007 BMW 335i
Fig. 197: Screws, Housing Cover And PCB

Remove switch unit (1) in upward direction.
Installation:
Switch unit (1) can only be installed in one position.
PCB (4) can be inserted turned through 180°.
Position of magnet sensor (3) of PCB (4) must match up with permanent magnet (2) of switch unit (1).
Fig. 198: Switch Unit, Permanent Magnet, Magnet Sensor And PCB
Remove guide (1) in upward direction.
Installation:
Guide (1) can only be installed in one position.
Fit seal (2) on guide (1) and insert in switch housing.

2007 BMW 335i
Fig. 199: Guide And Seal

IMPORTANT: Ignition key must be inserted in lock cylinder, otherwise this will be destroyed
when removed.
Insert ignition key in lock cylinder (2).
Carefully release catches (1) in outward direction and press out lock cylinder (2) with ignition key.
Installation:
Lock cylinder (2) can only be inserted in "ON" or "OFF" switch position.
Lock cylinder
Fig. 200: Lock Cylinder, Catches And Removal Direction

51 16 361 REPLACING RIGHT GLOVEBOX

2007 BMW 335i
 Remove right Glovebox with housing

 Remove Fastener For Glovebox
 Remove Damper For Glovebox
 Remove Glovebox Light
 If necessary, remove hotel setting switch
Release clips (1) and remove cover (2).
Fig. 201: Glovebox Clips And Cover

Remove all dummy platers.
Release screws (1) and remove locking catch (2) from glovebox housing.
Fig. 202: Glovebox Locking Catch And Screw

51 16 383 REMOVING AND INSTALLING/REPLACING DAMPER FOR GLOVEBOX

2007 BMW 335i
 Remove Glovebox With Housing
Open glovebox.
Release clip (1).
Fig. 203: Glovebox Clip

Press catch (1) together and slide damper (2) in direction of arrow.
Remove damper (2) in inward direction.
Fig. 204: Glovebox Catch, Damper And Removal Direction

Installation:
Catch (1) and guide (2) on damper (3) must not be damaged or missing.
2007 BMW 335i
Fig. 205: Glovebox Catch, Guide And Damper

51 16 383 INSTALLING AND REMOVING / REPLACING RIGHT GLOVE BOX DAMPER (WITH
AIRBAG)
Preliminary work needed:
 Remove the GLOVE BOX WITH HOUSING
Unscrew the circlips (1).
Remove the damper (2).
Installation note:
Circlips (1) must engage correctly.
Fig. 206: Identifying Damper And Circlips

51 16 480 REMOVING AND INSTALLING OR REPLACING FRONT GRAB HANDLE

2007 BMW 335i
Fold finishers down and unfasten screws.
Fig. 207: Grab Handle Finishers

LIDS
51 17 400 REMOVING AND INSTALLING/REPLACING BUMP STOP WITH EJECTOR FOR
FILLER FLAP
Release cover (1).
Press catches (2) together and pull out ejector (3).
Installation:
Install ejector (3) with fitted cover (1).
Fig. 208: Cover, Catches, Ejector And Removal Direction

Installation:
2007 BMW 335i
Catches (1) on ejector (2) must not be damaged.
Make sure cover (3) is correctly seated on ejector (2).
Fig. 209: Catches, Cover And Ejector

41 63 003 REPLACING COVER BOWL
 Remove FLAP FOR FUEL FILLER NECK

 Remove SERVODRIVE FOR TANK FILLER FLAP
 Remove FRONT WHEEL ARCH COVER (REAR SECTION)
Unscrew nut (1).
Installation:
Make sure seal (2) is correctly seated.

2007 BMW 335i
Fig. 210: Identifying Seal And Nut

Installation:
Clean contact surface on body and grounding lead on fuel filler pipe.
Ground connection must be guaranteed.
Release nuts (1).
Fig. 211: Identifying Nuts

Turn cover (1) through approx. 45° and lever out in direction of arrow.
2007 BMW 335i
Fig. 212: Removing Cover

Press retaining strap (1) inwards and remove.
Remove cover (2).
Remove rubber pad (3).
Insert a suitable tool through bores (3) and release catches.
Installation:
Make sure seal (4) is correctly seated.
Fig. 213: Removing Retaining Strap

Installation:
2007 BMW 335i
Catches (1) on ejector (2) must not be damaged.
Check protective cap (3) for correct seating.
Fig. 214: Identifying Catches, Ejector And Protective Cap

Installation:
Locks (1) on left/right of cover (2) must not be damaged.
Fig. 215: Identifying Locks And Cover

Close flap (1).
Twist cover bowl (2) in direction of arrow out of side panel and remove.
2007 BMW 335i
Fig. 216: Removing Cover Bowl

Installation:
Following parts on cover bowl (6) must not be damaged or missing:
1. Rubber pad
2. Catches, top/bottom
3. Spring
4. Catch
5. Guide
Fig. 217: Identifying Cover Bowl With Related Parts

LOCK CYLINDERS, ASSEMBLY

51 16 992 DISASSEMBLING AND ASSEMBLING LOCK CYLINDER (LOCK CYLINDER
2007 BMW 335i
REMOVED)
If necessary, remove LOCK CYLINDER
NOTE:  Lock cylinder repair kit (part number: 7 001 461) applicable to:
E46, E52, E53, E60, E61, E63, E64, E65, E66, E67, E85, E86, E90, E91, E92,
E93
Sort supplied retainers (1) by stamped numerical sequence (X) in ascending order and number (Y).
Fig. 218: Identifying Retainers In Numerical Sequence

Insert spring (1) into first lock cylinder position (2).
NOTE: Lock cylinder version (2) differs from vehicle to vehicle.
Fig. 219: Identifying Spring And First Lock Cylinder Position

2007 BMW 335i
Insert retainer (1) with lowest number (X) of first position (Y) in lock cylinder (2) and snap audibly into place.
NOTE: Number of retainers (1) differs from vehicle to vehicle.
Fig. 220: Identifying Retainer And Lock Cylinder

Insert ignition key (1) into lock cylinder (3) and check whether retainer (2) is flush with housing.
 (A) OK
 (B) not OK
Fig. 221: Checking Retainer Flush

If retainer (2) is not OK, press retainer (2) out of lock cylinder (3) with a suitable tool (1).
Continue with next number (X) higher of first position (Y) until retainer is OK.
2007 BMW 335i
The continue with all the other positions in accordance with the above-mentioned procedure.
Fig. 222: Pressing Retainer Out Of Lock Cylinder Using Suitable Tool
FRONT DOOR LOCKS, HANDLES, FITTINGS

51 21... REMOVING WINDOW CAVITY WEATHER STRIP WITH SPECIAL TOOL 00 9 324 AT
FRONT OR REAR
 00 9 318
 00 9 324
Open complete door window glass.
Front door:
Insert special tool 00 9 324 at front (at A-pillar) in window cavity (1) (letters TOP pointing upwards).
Rear door:
Insert special tool 00 9 324 at rear (at C-pillar) in window cavity (2) (letters TOP pointing upwards).
2007 BMW 335i
Fig. 223: Window Cavities, Special Tool (00 9 324) And Installation Direction
NOTE: For purposes of clarity, picture shows inner door panel and door window glass
removed.
Special tool 00 9 324 must be correctly guided under window cavity weather strip (1).
2 Short leg, bottom

3 Long leg, top (TOP)
Fig. 224: Window Cavity Weather Strip, Bottom Short Leg, Top Long Leg And Special Tool (00 9
324)
NOTE: Start at the front or rear, depending on the model.
Raise window cavity weather strip (3) no more than 5 mm in each levering
operation, otherwise the strip will be bent.
2007 BMW 335i
Position special tool 00 9 318 on door trim panel (1).
Slide screwdriver (2) into special tool 00 9 324 and lever window cavity weather strip (3) upwards no more than
5 mm.
Guide special tools 00 9 324 and 00 9 318 towards front/rear and lever out window cavity weather strip (3) in
the process.
Fig. 225: Trim Panel. Screwdriver, Cover Strip, Removal Direction, Special Tools (00 9 318) And (00 9
324)
51 21... OVERVIEW OF FRONT DOOR LOCKS

2007 BMW 335i
Fig. 226: Front Door Locks Components

51 21 003 REPLACING DOOR DETENT (LOCK STRIKER), FRONT LEFT OR RIGHT
Release screws (1) and remove door detent (2).
Installation:
If necessary, carry out basic adjustment by way of notches (3) on door detent (2).
Notches (3) must be vertical to B-pillar.
Adjust Door Detent.

2007 BMW 335i
Fig. 227: Notches And Door Detent

51 21 004 ADJUSTING FRONT LEFT OR RIGHT DOOR DETENT (LOCK WEDGE)
Adjusting Left Or Right Front Door.
51 21 090 REMOVING AND INSTALLING/REPLACING DOOR LOCK IN LEFT OR RIGHT FRONT

DOOR
 51 2 190
 Remove rear section of Power Window Unit
Driver's side only:
 Remove Lock Cylinder Lock Cylinder
Unclip lock knob control rod (1).
Unlock and disconnect plug connection (2) at lugs (3).

2007 BMW 335i
Fig. 228: Lock Knob Control Rod, Lugs And Plug Connection
Unhook Bowden cable (1) from door lock (2).
If necessary, release cable holder on door lock (2).
Installation:
Bowden cable (1) must be correctly engaged in locators in door lock (2).
Bowden cable (1) must be laid without kinks in bend to door lock (2).
IMPORTANT: Door cannot be opened if Bowden cable (1) is incorrectly laid.
Fig. 229: Bowden Cable And Door Lock

IMPORTANT: Do not damage door lock seal when removing.
Release screws (1).

2007 BMW 335i
Remove door lock (2) from inside.
IMPORTANT: To avoid leaking and electrical malfunction:
Pull door lock (2) with special tool into corner (3), refer to illustrations Fig. 233
and Fig. 234.
Fig. 230: Door Lock, Screws And Door Corner

Installation:
Seal (1) on door lock (2) must not be damaged.
Fig. 231: Seal And Door Lock

E90/E91 driver's side only:
NOTE: Cover (1) protects against water ingress.
In event of problems with frozen door locks/lock cylinders, retrofit cover (1) on
2007 BMW 335i
door lock (2) if necessary.
Fig. 232: Cover And Door Lock

Installation:
 Install door lock and insert screws (1), do not tighten down.
 Slide special tool 51 2 190 into opened rotary latch until latch engages in first stage.
Fig. 233: Door Lock, Screws And Special Tool (51 2 190)
Installation:
 Pretension door lock (1) with knurled screw (2) until special tool 51 2 190 just contacts corner points (3).
IMPORTANT: To tension door lock (1), it is only permitted to turn knurled screw (2) by a
further 1 to 1.5 turns (max.) (risk of damage).
Door lock seal must rest uniformly on inner door plate (water ingress).
 Tighten down door lock screws, for tightening torque refer to 51 21 1AZ in 51 21 FRONT DOOR
2007 BMW 335i
LOCKS .
Fig. 234: Door Lock, Corner Points, Knurled Screw And Special Tool (51 2 190)
51 21 125 REMOVING AND INSTALLING/REPLACING CARRIER FOR LEFT OR RIGHT

OUTSIDE DOOR HANDLE WITH LOCK CYLINDER
 Remove Outside Handle

 Remove Sound Insulation
Release Bowden cable (1) from door lock (2).
Installation:
Bowden cable (1) must be correctly engaged in locators in door lock (2).
Bowden cable (1) must be laid without kinks in bend to door lock (2).
IMPORTANT: Door cannot be opened if Bowden cable (1) is incorrectly laid.

2007 BMW 335i

Remove seals (1) in direction of arrow.
Release screw (2).
Fig. 236: Door Lock Seals, Screws And Removal Direction

If necessary, release cable holder on carrier (1).
Remove inner carrier (1) in direction of arrow and feed out of door.
2007 BMW 335i
Fig. 237: Inner Carrier And Removal Direction

Replacement:
If necessary, release cable connector (1).
Feed Bowden cable (2) out of carrier (3).
Fig. 238: Bowden Cable, Carrier And Cable Connector

51 21 126 REMOVING AND INSTALLING/REPLACING CARRIER FOR LEFT OR RIGHT

OUTSIDE DOOR HANDLE WITHOUT LOCK CYLINDER
 Removing and installing/replacing Carrier For Outside Door Handle With Lock Cylinder .
51 21 140 REMOVING AND INSTALLING/REPLACING COMPLETE LOCK CYLINDER IN LEFT

OR RIGHT FRONT DOOR
Lever out seal (1) and release screw in area (A).

2007 BMW 335i
Installation:
Make sure seal (1) is correctly seated on door.
Fig. 239: Door Lock Cylinder Seal, Screw Area And Removal Direction
Pull off cover (1) with ignition key in direction of arrow with outside door handle (2) opened slightly.
Fig. 240: Door Handle, Cover And Removal Direction

Version with light package:
Installation:
Make sure outside door handle light (1) is correctly positioned in area (2).
Guides (3) of outside door handle light (1) must be correctly seated in carrier for outside door handle (4).
2007 BMW 335i
Fig. 241: Outside Door Handle, Light, Positioning Area And Guides
Remove catches (1) and detach cover (2) from lock cylinder (3).
Installation:
Catches (1) of cover (2) must not be damaged.
Paddle (4) of lock cylinder (3) must not be damaged.
Fig. 242: Catches, Cover, Paddle, Lock Cylinder And Removal Direction
51 21 147 REPLACING LOCKS FOR SIMULTANEOUS CLOSING WITH CAS CONTROL UNIT
Necessary tasks
 Replace COMPLETE LOCK CYLINDER FOR LEFT OR RIGHT FRONT DOOR

 Replace INSERT FOR RADIO CONTROL KEY
 Replace CONTROL UNIT FOR CAR ACCESS SYSTEM
2007 BMW 335i
Except E81, E87, E91:
 Replace lock for rear lid
Except E81, E82, E87 from MY 03/2007, E88:
 Replace LOCK FOR RIGHT GLOVEBOX
51 21 150 BLOCKING, IF NECESSARY INITIALIZING, CAR KEY IN IMMOBILIZER CONTROL

MODULE
NOTE: Execution in diagnosis system:
-->Service functions-->
-->Body-->
-->Locking and security functions-->
-->Remote control key
51 21 150 REPLACING LOCKS FOR SIMULTANEOUS CLOSING WITH CAS CONTROL UNIT
 Replace complete lock cylinder for left or right front door

 Replace Insert For Radio Control Key
 Replace Control Unit For Car Access System
Except E81, E87, E91:
 Replace Lock For Rear Lid
Except E81, E82, E87 from MY 03/2007:
 Replace lock for right glovebox
51 21 170 REMOVING AND INSTALLING OR REPLACING OUTSIDE HANDLE FROM LEFT OR

RIGHT FRONT DOOR
 Remove Cover On Outside Handle
If necessary, lay outside door handle light (1) slightly to one side.
Pull out outside handle (2) and feed out in direction of arrow.
2007 BMW 335i
Version with Comfort Access/CA:
Carefully feed out outside handle (2) and disconnect associated plug connection. SCP-3100
Fig. 243: Outside Door Handle, Light And Removal Direction

Installation:
Locator (1) must not be damaged.
Version with Comfort Access/CA:
Fig. 244: Door Handle Locator And Seal

Installation:
Seals (1 and 2) must not be damaged.
If necessary, pull lock actuator (3) outwards until it engages retaining clasp (4).
2007 BMW 335i
Install outside handle and insert correctly in to lock actuator (3).
Outside handle is in the correct position only after the cover has been fitted on the outside handle.
Carry out function check only with door open.
Fig. 245: Door Seals, Lock Actuator And Retaining Clasp

If replacing version with comfort access/CA:
Reset CAS control unit with diagnosis system or by disconnecting and connecting Battery .
51 21 180 REMOVING AND INSTALLING/REPLACING COVER ON OUTSIDE HANDLE
Lever out seal (1) and release screw in area (A).
Installation:
Make sure seal (1) is correctly seated on door.
Fig. 246: Outside Door Handle Seal, Screw Area And Removal Direction
2007 BMW 335i
Pull off cover (1) in direction of arrow with outside door handle (2) opened slightly.
Fig. 247: Outside Door Handle, Cover And Removal Direction

Version with light package:
Installation:
Make sure outside door handle light (1) is correctly positioned in area (2).
Guides (3) of outside door handle light (1) must be correctly seated in carrier for outside door handle (4).
Fig. 248: Guides, Positioning Area, Outside Door Handle And Outside Door Handle Light
Installation:
Guides (1) must not be damaged.

2007 BMW 335i
Fig. 249: Outside Door Handle Guides

51 21 181 REMOVING AND INSTALLING/REPLACING COVER ON OUTSIDE HANDLE WITH

LOCK CYLINDER
Removing and installing/replacing Complete Lock Cylinder in left or right front door.
51 21 225 REMOVING AND INSTALLING OR REPLACING INSIDE DOOR OPENER IN LEFT OR

RIGHT FRONT DOOR
 Remove front Door Trim Panel
Unhook Bowden cable for release lever:
 Lever out lock (2) upwards

 Detach Bowden cable (3) towards rear/top.
Installation:
For fitting, press release lever (1) fully onto door trim panel.
2007 BMW 335i
Fig. 250: Door Lock, Bowden Cable, Lever And Removal Directions
Release screws (1).
Release catches (2) and remove door opener (3).
Fig. 251: Door Opener, Catches And Screws

Installation:
Catches (1) on door opener (2) must not be damaged.

2007 BMW 335i
Fig. 252: Door Opener And Catches

51 21 233 REMOVING AND INSTALLING/REPLACING BOWDEN CABLE FOR OUTSIDE DOOR

HANDLE ON LEFT OR RIGHT FRONT DOOR
Removing and installing/replacing Carrier For Left Or Right Outside Door Handle .
51 21 235 REMOVING AND INSTALLING/REPLACING BOWDEN CABLE FOR INSIDE DOOR

OPENER ON LEFT OR RIGHT FRONT DOOR
Unhook Bowden cable for release lever:
 Tighten release lever (1).

 Lever out lock (2).
 Detach Bowden cable (3) towards rear/top.
Installation:
For fitting, press release lever (1) fully onto door trim panel.
2007 BMW 335i
Fig. 253: Bowden Cable, Lock, Release Lever And Removal Direction
51 21 280 REMOVING AND INSTALLING OR REPLACING DOOR STOP ON LEFT OR RIGHT

FRONT DOOR
 Close door windows

 Remove Sound Insulation in front area
NOTE: Secure front door against falling closed.
Release screw (1).
For tightening torque refer to 51 21 3AZ in 51 21 FRONT DOOR LOCKS.
For tightening torque refer to 51 21 4AZ in 51 21 FRONT DOOR LOCKS.
Remove seal (3).
Installation:

2007 BMW 335i
Fig. 254: Door Seal And Screws

Remove door retainer (1) via cutout (2).
Fig. 255: Door Retainer, Cutout And Removal Direction

Installation:
Following parts of door retainer (3) must not be damaged:
1. Hinge
2. Thread
2007 BMW 335i
Fig. 256: Door Retainer, Hinge And Thread

51 21 300 REMOVING AND INSTALLING OR REPLACING WINDOW CAVITY WEATHER STRIP

ON OUTSIDE OF LEFT OR RIGHT FRONT DOOR
 00 9 324
IMPORTANT: Observe Procedure for using special tool 00 9 324 .
The "Instructions on fitting window guides" serve as the basis for this repair
instruction and must be observed without fail.
If reusing the existing window cavity weather strip (1), make sure it is not bent.
Lever out window cavity weather strip (1) with special tool 00 9 324 (starting at B-pillar).
Fig. 257: Window Cavity Weather Strip And Removal Direction

2007 BMW 335i
Pull window cavity weather strip (1) out of door mirror (2) in direction of arrow.
Installation:
Moisten window cavity weather strip (1) prior to fitting with Approved Anti-Friction Agent.
Fig. 258: Window Cavity Weather Strip, Door Mirror And Removal Direction
E92/E93 only:
Installation:
Notch (1) on window cavity weather strip (2) must be correctly located in guide (3) of cover strip (4).
window cavity weather strip (2) must be flush at rear to door edge (5).
If cover strip (4) is not correctly fitted, window cavity weather strip (2) cannot be fitted flush with door edge
(5).
If necessary, align cover strip (4).

2007 BMW 335i
Fig. 259: Window Cavity Weather Strip, Notch, Cover Strip, Guide And Door Edge
51 21 301 REMOVING AND INSTALLING/REPLACING WINDOW CAVITY WEATHER STRIP ON

OUTSIDE OF FRONT DOOR
 00 9 322
IMPORTANT: The "Instructions On Fitting Window Guides" serve as the basis for this repair
 Remove Mirror On Front Door
Pop catch (1) out of window guide (2) of door.
Pull window guide (2) approx. 30 mm upwards.
Carefully lever window cavity weather strip (3) with special tool 00 9 322 out of door.
Installation:
Catch (1) must not be damaged.
window cavity weather strip (3) must be flush at front to door.

2007 BMW 335i
Fig. 260: Catch, Door Window Guide, Window Cavity Weather Strip, Special Tool (00 9 322) And
Removal Direction
51 21 330 REMOVING AND INSTALLING/REPLACING WINDOW CAVITY WEATHER STRIP ON

INNER FRONT DOOR
IMPORTANT: The "Instructions On Fitting Window Guides" serve as the basis for this repair
 Remove outer window cavity weather Strip

Pop cover strip (1) in direction of arrow out of front door.
Fig. 261: Front Door Window Cavity Weather Strip And Removal Direction
Installation:
2007 BMW 335i
Molded section (1) and retaining elements (2) of window cavity weather strip (3) must not be damaged.
Molded section (1) must be correctly fed into door.
Fig. 262: Molded Section, Retaining Elements And Window Cavity Weather Strip
Installation:
Make sure cover strip (1) is installed in correct position on door (2) and door window glass (3).
Fig. 263: Window Cavity Weather Strip, Door Window Glass And Cover Strip Position
HOOD LATCH, LOCKS

51 23... ADJUSTING/REPLACING BUMP STOPS
The illustrations are schematic representations and are to be applied to the relevant vehicle type.
2007 BMW 335i
Version 1:
Following parts must not be damaged:
 Bump stop
Fig. 264: Bump Stop

Adjust bump stop (1) to correct height by turning left or right.
Fig. 265: Adjusting Bump Stop

Version 2:
Replace damaged bump stops (refer to EPC):
 Bump stop with ejector

2007 BMW 335i
Fig. 266: Bump Stop With Ejector

Press ejector (1) into bump stop and, in this position, twist approx. 90° counterclockwise with a Phillips
screwdriver.
This locks the ejectors (1) in the bump stops.
Adjust bump stop (2) to correct height by turning left or right.
Unlock the ejector (1) again after completing adjustment.
Fig. 267: Ejector And Bump Stop

Version 3:
Replace damaged bump stops (refer to EPC):
 Bump stop
2007 BMW 335i
Fig. 268: Bump Stop

Turn lock (1) 45° counterclockwise.
Pull bump stop (2) upwards.
Close lid slowly until it is at the same height as the side panel.
Open lid and turn lock (1) clockwise.
Installation:
Press bump stop in to panel and drive in expanding pins (3).
Fig. 269: Lock, Bump Stop, Expanding Pins, And Installation Direction
51 23... CHECK ACTUATOR
 Remove actuator
2007 BMW 335i
Check actuator (1) for damage.
Test result Solution

Housing damaged Replace actuator
Fig. 270: Checking Actuator For Damage

51 23... REMOVING/INSTALLING BALL SOCKETS WITH CLIP
WARNING: Risk of injury! When installed, the gas pressurized shock absorber is
under preload. Minimize preload as far as possible before removing.
IMPORTANT: Never lift off ball socket with engaged retainer.
Disassembly/assembly:
1. Push on retainer in direction of groove with screwdriver

2. Lift off ball socket from ball pin
3. Slide retainer back
4. Fit ball socket on ball stud and snap into place with force
Installation:
Replace overstretched clips.
Pack grease into two opposite positions in socket. The grease spreads after installation on the ball pin all round
in the ball socket.
2007 BMW 335i
Fig. 271: Fitting Ball Socket On Ball Stud

51 23 004 ADJUSTING ENGINE COMPARTMENT LID CATCH
 Adjusting Hood/Bonnet
51 23 100 REMOVING AND INSTALLING/REPLACING RIGHT ENGINE HOOD LOCK
 Remove front Intake Duct
Unclip coupling (1) from side panel.
Lever out cover (2) at coupling (1).
Lever Bowden cable (3) out of coupling (1).
NOTE: The operation "Disconnect cable for hood/bonnet locks" ends here.
2007 BMW 335i
Fig. 272: Coupling, Cover And Bowden Cable

Fig. 273: Screws And Bumper Trim

Release Bowden cable (1) from holder (2).

2007 BMW 335i
Fig. 274: Bowden Cable And Holder

Release screws (1).
For tightening torque refer to 51 23 2AZ. in 51 23 HOOD/BONNET LOCKS
Carefully pull bumper (2) forwards and feed out hood/bonnet lock (3) with cable.
Fig. 275: Screws, Bumper Trim And Hood/Bonnet Lock

Disengage cable (1) from hood/bonnet lock (2).
When replacing cable for hood/bonnet locks:
Feed cable (1) out of front wall (3).
Fig. 276: Front Wall, Cable And Hood/Bonnet Lock

51 23 110 REMOVING AND INSTALLING/REPLACING LEFT HOOD LOCK

2007 BMW 335i
Lever cable (3) out of coupling (1).
NOTE: The operation "Disconnect cable for hood/bonnet locks" ends here.
Fig. 277: Hood/Bonnet Lock Coupling, Cover And Cable

Release screws (1).
Fig. 278: Screws

Release screws (1).
Carefully pull bumper (2) forwards and feed out hood/bonnet lock (3) with cable.
For tightening torque refer to 51 23 2AZ in 51 23 HOOD/BONNET LOCKS.

2007 BMW 335i
Fig. 279: Screws, Bumper And Hood/Bonnet Lock

Disengage cable (1) from hood/bonnet lock (2).
When replacing cable for hood/bonnet locks:
Feed cable (1) out of front wall.
Fig. 280: Cable And Hood/Bonnet Lock

51 23 131 ADJUSTING LEFT OR RIGHT STRIKER ON ENGINE HOOD
 Adjusting Hood/Bonnet
51 23 155 REMOVING AND INSTALLING/REPLACING BAR FOR RETAINING HOOK
 Remove Front Bumper

2007 BMW 335i
Release screws (1) and clips (3).
Remove in take cover (2).
Fig. 281: Clips, Intake Cover And Screws

Release screws (1) on bar (2).
Fig. 282: Retaining Screws And Bar

Release catches (1) on cooling air guide (2).
Feed out cooling air guide (2) with bar towards front.
Feed bar out of cooling air guide (2).

2007 BMW 335i
Fig. 283: Catches, Cooling Air Guide And Removal Direction

51 23 160 REMOVING AND INSTALLING/REPLACING ARRESTER HOOK ON ENGINE HOOD
Raise bonnet/hood lid.
Release screws (1) and remove arrester hook (2).
For tightening torque refer to 51 23 1AZ in 51 23 HOOD/BONNET LOCKS.
Fig. 284: Mounting Screws And Arrester Hook

51 23 211 REMOVING AND INSTALLING/REPLACING CABLE FOR FRONT ENGINE HOOD

LOCKS (TO PASSENGER COMPARTMENT)
 Remove footwell side trim panel

 Remove Lower Section Of Microfilter Housing On Left .
2007 BMW 335i
Disengage Bowden cable (1) from release lever (2) and feed out in direction of arrow.
Fig. 285: Bowden Cable, Release Lever And Removal Direction

Release expander rivet (1) and nut (2).
Feed out water channel (3) towards top.
Installation:
Make sure water channel (3) is correctly seated.
Fig. 286: Expander Rivet, Nut And Water Channel

Feed out Bowden cable (1) in direction of engine compartment.
Installation:
Lay Bowden cable (1) without kinks.

2007 BMW 335i
IMPORTANT: Grommet (2) must not be damaged.
Check that grommet (2) is correctly seated (water ingress).
Fig. 287: Bowden Cable, Grommet And Removal Direction

Lever Bowden cable (3) out of coupling (1) and remove.
Fig. 288: Coupling, Bowden Cable And Cover

51 23 212 REMOVING AND INSTALLING/REPLACING CABLE FOR FRONT HOOD LOCKS (TO
LOCKS)
 Remove Left/Right hood/bonnet locks

2007 BMW 335i
51 23 265 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT GAS STRUT FOR

ENGINE HOOD
WARNING: Risk of injury and damage!
For the following tasks, you must take the appropriate measures to
support the engine bonnet/hood.
As an alternative, you can enlist the help of a second person to hold the
bonnet/hood.
Raise bonnet/hood lid.
Removing gas spring strut at top and bottom:
1. Push retainer spring to end of gas spring strut.

2. Remove gas spring strut from ball head.
Fig. 289: Retainer Spring, Gas Spring Strut And Removal Directions
51 23 400 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT ACTUATOR (ACTIVE

PEDESTRIAN PROTECTION)
WARNING: Adhere to SAFETY PRECAUTIONS so as to avoid a danger of injury by the

actuator. The BATTERY NEGATIVE LEAD must be clamped off prior to
work on the actuator or engine compartment lid! Do not exert any force
on the actuator. Incorrect handling may result in triggering of the actuator
and thereby cause serious injury.
Disconnect negative battery cable. Remove COWL PANEL COVER.

2007 BMW 335i
Lever out clip (1).
Release screws (2) and remove cavity sealing (3).
Fig. 290: Identifying Clip, Screws, And Cavity Sealing

Tightening torque: 7, 6 Nm
2007 BMW 335i
Fig. 291: Identifying Actuator, Bolt, And Connector

TRUNK LATCH, LOCKS

51 24 004 ADJUSTING REAR LID LOCK (LOWER SECTION OF REAR LID LOCK)
NOTE: Rear lid must be correctly adjusted to fit before adjustment of rear lid lock.
If necessary Adjust Rear Lid .
For ideal adjustment, refer to Body gap dimensions .
Screw in detent buffers for rear lid on left/right completely.

2007 BMW 335i
Fig. 292: Detent Buffers Screws

Check fulcrum pads on lower section of rear lid lock for damage and replace if necessary.
Fig. 293: Lower Section Rear Lid Lock Fulcrum Pads

Version with cover caps on rear apron trim:
If necessary, remove cover caps.
Slacken screws in lower section of rear lid lock until it is just able to move and centers itself.
The lower section of the rear lid lock must not scrape against the rear lid lock.
2007 BMW 335i
Fig. 294: Rear Lid Lock Screws

NOTE: Adjusting lower section of rear lid lock:
Close trunk lid.
This enables the lower section of the rear lid lock to adjust itself correctly.
Open rear lid.
Tighten down screws on lower section of rear lid lock.
Check adjustment of rear lid and rear lid lock, repeating adjustment if necessary.
Fig. 295: Rear Lid Lock Screws

Unscrew detent buffer until closed rear lid abuts against left/right detent buffers.
IMPORTANT: The rear lid must not be higher than the side panels, otherwise there is preload
on height adjustment!
2007 BMW 335i
Fig. 296: Detent Buffer Screws

51 24 004 ADJUSTING REAR LID LOCK (CONVERTIBLE)
Prerequisite:
Rear lid must be correctly adjusted to fit; if necessary, adjust REAR LID .
For ideal adjustment, refer to BODY GAP DIMENSIONS.
NOTE: The operation is shown on the left side; proceed in the same way for the right
side.
 Remove trim for support tube:
Release clips (1).
Feed out panel (2) in direction of arrow.
Installation:

2007 BMW 335i
Fig. 297: Identifying Feed Out Panel And Clips

Slacken screws (1) until striker (3) can be moved.
Slide striker (3) in direction of arrow.
Check alignment of rear lid and striker, readjust if necessary.
If necessary, remove shims (2) or insert additional.
Fig. 298: Checking Alignment Of Rear Lid And Striker

41 00... Gap dimensions, body
NOTE: Symmetry of the gaps between left and right sides of the vehicle has top
2007 BMW 335i
priority.
The door gaps must not deviate between the front and rear gap by more than 1.0 mm.
Dimensions in mm
Fig. 299: Identifying Gaps Dimension

2007 BMW 335i
Dimension (1) 0.8 ± 0.8 is reduced in the rearward direction of travel to 0 ± 0.8
Dimension (2) 1.5 ± 1.0 is reduced in the downward direction to 0 ± 1.5
Dimension (3) 0 ± 0.7 is reduced in the forward direction of travel to 2.5 ± 0.7

2007 BMW 335i
Dimensions in mm

2007 BMW 335i
Dimension (1) may have a differential from left to right of max. 1.1 mm.

Dimension (1) may have a differential from front to rear of max. 1.1 mm.
2007 BMW 335i

Dimension (1) may have a differential from left to right of max. 1.1 mm.
2007 BMW 335i

51 24 050 REMOVING AND INSTALLING/REPLACING LOCK ELEMENT (LOCK CYLINDER)

FOR REAR LID
Except E93:
E93 only:
Release clips (1) and feed out left cover (2) in direction of arrow.
2007 BMW 335i
Fig. 305: Retaining Clips, Left Cover And Removal Direction

Unclip cover (1) in outward direction.
Fig. 306: Cover And Removal Direction

Disconnect Bowden cable (1).
Insert 2 mm dia. punch into hole (A) and press down catch (3).
Turn lock (2) counterclockwise through 90° and remove punch.
Release screws (4) and remove lock element (5) inwards.
Installation:
Position lock element (5) on rear lid and secure with screws (4).
Turn lock (2) 90° to right.
Press lock element (5) on rear lid until seal is correctly positioned.
2007 BMW 335i
Fig. 307: Bowden Cable, Lock Element, Screws, Hole, Lock And Catch
For tightening torque refer to 51 24 3AZ in 51 24 REAR LID LOCKS.
Installation:
Seal (1) on lock element (2) must not be damaged.
Perform function check with rear lid open.
Fig. 308: Seal And Lock Element

51 24 100 REMOVING AND INSTALLING/REPLACING REAR LID LOCK (UPPER SECTION)
Release screws (2) and feed out upper section of rear lid lock (3).
2007 BMW 335i
Installation:
Use self-tapping screws.
Fig. 309: Plug Connection, Screws, Upper Rear Lid Lock And Removal Direction
Remove lock (1).
Lever out actuating rod (2) and remove upper section of rear lid lock (3).
Installation:
Make sure lock (1) is correctly seated.
Fig. 310: Lock, Actuating Rod, Upper Rear Lid Lock And Removal Direction
Installation:

2007 BMW 335i
51 24 100 REMOVING AND INSTALLING/REPLACING REAR LID LOCK (CONVERTIBLE)
 Remove panel for rear lid
Left side:
Disconnect plug connection (2) on rear lid lock (4).
Release screws (3).
Fig. 311: Identifying Plug Connection And Rear Lid Lock (Left Side)
Right side:
Disconnect plug connection (1) on rear lid lock (3).
Release screws (4) and fold rear lid lock down (3) slightly.
2007 BMW 335i
Fig. 312: Identifying Plug Connection And Rear Lid Lock (Right Side)
Unclip holder (1) with screwdriver (2).
Unhook Bowden cable (4) from lever (3).
Remove rear lid lock (5).
Fig. 313: Unhooking Bowden Cable From Lever

51 24 130 REMOVING AND INSTALLING/REPLACING STRIKER FOR REAR LID LOCK

(COUPE)
 Remove Trim On Tail Panel
Release screws (1) and remove striker.

2007 BMW 335i
For tightening torque refer to 51 24 2AZ in 51 24 REAR LID LOCKS.
Installation:
Adjust striker .
Fig. 314: Striker Retaining Screws

51 24 131 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT STRIKER FOR REAR

LID LOCK (CONVERTIBLE)
 Remove trim on support tube:
Release clips (1).
Installation:

2007 BMW 335i

Release screws (1).
Remove shims (2) and striker (3).
Installation:
Adjust STRIKER.
Fig. 316: Checking Alignment Of Rear Lid And Striker

51 24 145 REMOVING AND INSTALLING/REPLACING BUTTON FOR REAR LID ACTUATION
 00 9 323
2007 BMW 335i
Move special tool 00 9 323 under front edge of button (1) and lever out button (1).
Pull button (1) out of rear lid (2).
Fig. 317: Button, Rear Lid, Special Tool (00 9 323) And Removal Direction
Disconnect plug (1) and remove button (2).
Installation:
Fig. 318: Plug And Button

Replacement:
Carefully release catches (1) and remove microswitch (2).

2007 BMW 335i
Fig. 319: Catches And Microswitch

51 24 300 REMOVING AND INSTALLING OR REPLACING LEFT OR RIGHT GAS STRUT FOR
REAR LID (COUPE)
When removing both gas struts, support rear lid in fully open position
with suitable apparatus.
Open rear lid.
Make a written record of the alignment of gas strut (2) before removing.
Slide stop spring (1) to end of gas strut (2) and lever out gas strut (2).
Repeat the procedure at the other end of the gas strut (2) and remove.
Fig. 320: Stop Spring, Gas Strut And Removal Direction

2007 BMW 335i
51 24 300 REMOVING AND INSTALLING OR REPLACING LEFT OR RIGHT GAS STRUT FOR
REAR LID (CONVERTIBLE)

Support rear lid in fully opened position with suitable apparatus.
Make a written record of the alignment of gas strut (2) before removing.
Slide stop spring (1) to end of gas strut (2) and lever out gas strut (2).
Repeat the procedure at the other end of the gas strut (2) and remove.
Right side only:
Feed gas strut (2) out of cable guide (3).
Installation:
Make sure cable guide (3) is correctly seated on gas strut (2).
Fig. 321: Sliding Stop Spring To End Of Gas Strut And Lever Out Gas Strut
FRONT AND REAR WINDOW

51 31... NOTES ON WINDOW BONDING; WORK STEPS FOR REMOVING AND INSTALLING
WINDOW GLASS
NOTE: If the document for the selected model is not required or not approved, the
following message will be displayed when clicking on the "cross-reference":
"No additional documents available in the current vehicle context".
The following notes are mandatory and must be observed.

2007 BMW 335i
These notes are not applicable to side window bonding (door "center") on the E38/L7:
General
 The vehicle can be towed away or driven without a windscreen, rear window and side window.
The windscreen, rear window and side windows are glued to the body. This bonding will increase the torsional
rigidity of the vehicle. To obtain perfect bonding, comply with the installation procedure described in the
following.
 The adhesive must be applied at room temperatures > 15°C to avoid negatively affecting the bonded
connection.
Adjust the component and interior temperature accordingly.
 A relative humidity of < 30% significantly slows hardening.

 The window glass must be secured against slipping with yellow plastic adhesive tape after being installed.
The paint must be completely hardened after painting work.
 Always apply the adhesive in such a way as to achieve tension-free bonding!
On-the-job safety
When working with bonding products (adhesive, cleaning agent, bonding agent, etc.):

 Change work clothing contaminated with adhesive immediately.
 Change work clothing contaminated with solvents and swelling agents immediately (keep spare work
clothing on hand).
 Take skin protection measures, provide washing facilities including hot water, use silicone-free skin
creams
 Provide eye douche facilities, change water regularly (once a month).
 Comply with the relevant safety regulations
 Do not eat, drink or smoke in areas of polyurethane processing.
 All use and safety information of the safety data sheet (SDB) for the applicable product apply. The safety
data sheet (SDB) can be obtained from the Aftersales Assistance Portal (ASAP)
Replacement of windscreens
Version with Head-Up Display (HUD):
 Marking for HUD must be present on the windscreen
Version with front passenger airbag:

2007 BMW 335i
 Stick on LABEL
Tools for cutting through adhesive bead:
ADHESIVE BEAD CUTTING TOOL REFERENCE CHART

Type Type Order/part number
Special cutter (manufacturer: Fein) Compressed air operated 7 23 63 100 23 8
with oscillating knife Electrically operated 7 53 60 200 00 4
BMW knife set All required knives PN 81 43 9 428 596 or
6 39 03 167 05 4
Knife (U-shape) 19.5 mm (1) 6 39 03 118 01 3
24 mm 6 39 03 076 01 6
36 mm 6 39 03 079 01 2
45 mm 6 39 03 154 01 0
Knife (straight with stop roller) 16 to 35 mm (adjustable) 6 39 03 143 01 3
10 mm (fixed) (1) 6 39 03 189 01 0
14 mm (fixed) 6 39 03 082 01 6
"ROLL OUT 2000" Window Wire cutting system (1) PN 81 62 0 301 768
glass repair
Cutting wire Wire cutting system (1) PN 83 19 2 150 267
Scalpel for heavy-duty applications (1)
Handles for cutting wire Self-locking (1) Special tool 51 3 270
(1) not included in BMW blade set
Storage temperature
Storage temperature of all adhesive products of more than 15°C must be observed.
Adhesive
The BMW approved polyurethane adhesive must be used for bonding:
 Window glass adhesive (Part number 83 19 0 444 144*)

 Small repair kit (part number 83 19 0 444 141*)
 Large repair kit (part number 83 19 0 444 145*)
* Sourcing reference: BMW Parts Department
The repair kit, large contains a second window glass glue cartridge.
Adhesive is applied to window glass with cartridge gun (Compressed Air operated or Electrically operated).
Adhesive expiry date

2007 BMW 335i
Repair kit (A) and glue cartridges (B) are marked with a date (best before).
Date (1) refers to the calendar week and year (KW/JJJJ).
Fig. 322: Identifying Expiration Date On Repair Kit And Glue Cartridges
The adhesive cannot be used after this date (1).
Adhesive disposal
Pure hardened adhesive is handled as normal waste.
The adhesive is disposed of in paper sacks so that it can react with moisture.
Non-hardened adhesive, cartridges and mixtures of adhesive and solvents and the like must be disposed of as
hazardous waste.
Bonding agent (glass activator)
The BMW-approved bonding agents must be used to treat adhesive areas:
 Glass Activator (on ceramic glass), yellow stick, BMW part number: 83 19 0 444 142
 Paint Activator (on sheet metal flange or residual adhesive bead), blue stick, BMW part number: 83 19 2
154 458
WARNING: Wear cut resistant gloves when breaking the glass ampoule
Prepare Glass Activator (2) and Paint Activator (B) for application by shaking and kinking (breaking glass
2007 BMW 335i
ampoule).
Apply Glass Activator (2) by pressing gently. There is no need for final wiping. Air drying time approx. 2
minutes.
Apply Paint Activator (B) by pressingly gently. Then wipe dry with a paper towel (included in the set).
Bonding agent expiry date
Repair kit and bonding agent are marked with a date (Best Before).
 The bonding agent may only be used up to this date (if not already opened previously).
 After opening, keep only for one week even if the expiry date has not yet been reached.
NOTE: Write the date on the bottle when opening the bonding agent for the first time.
Close the bottle immediately after extracting the bonding agent (reaction with
air).
Application of bonding agent
The bonding agent is used for adhesion between glass or ceramic glass and the adhesive. Therefore, a thin,
homogeneous and continuous line of bonding agent must be applied.
After compressing the adhesive bead, make sure that there is 1 to 2 mm wide bonding agent trace is on the
ceramic glass next to the adhesive bead (serves visual inspection).
The adhesive bead may become up to 15 mm wide in compressed condition. The width of the adhesion agent is
therefore at least 17mm with windscreens and rear windows and at least 9 mm with door window glass.
The bonding agent may not be applied in the visible area or the point grid. Fresh bonding agent in the visible
area must immediately be wiped off with solvent because hardened bonding agent will leave a haze behind.
ADHESIVE APPLICATION REFERENCE CHART

Graphic A Graphic B
Window glass with cover Window glass without cover.
If the adhesive bead (1) cannot expand further (a = 0 If the adhesive bead (1) can expand into both
mm) into one direction when pressing down, the directions while pressing down, the bonding agent
outer edge of the bonding agent bead (3) will run (3) and adhesive bead (2) will run toward each other
through Point a. in the center (m).
2007 BMW 335i
Fig. 323: Identifying Adhesive Bead And Bonding Agent Bead

Removal of window glass
IMPORTANT: As of E63 and E87 it will only be possible to remove the rear window with the
""ROLL OUT 2000"".
Cover side walls, roof-mounted aerial and if necessary interior equipment with protective covers.
Tape off body with fabric adhesive tape (e.g. Tesa) in those areas where the oscillating blade could damage the
window glass or the paint.
When using the cutting wire, pull the cutting wire ends through special tool 51 3 270 , bend and tape off with
fabric adhesive tape (e.g. Tesa) (risk of injury and damage).
When removing the window glass:
 Wear safety goggles and protective gloves.
Cut through adhesive bead of window glass:
 With ""ROLL OUT 2000"" (wire cutting system); no paint is damaged here in the case of narrow gaps
 with special cutter and oscillating knife
Prior to each use, regrind the knife with a grindstone while the machine is running (new knives also).
Avoid paintwork damage on body aperture.
Guide knife carefully between body and window glass.

2007 BMW 335i
Run blade of knife parallel to window glass.
Cut through adhesive bead as closely as possible to window glass.
To remove residual adhesive bead in body aperture (and on window glass if reusing):
 Use a scalpel for heavy-duty applications

 Cut off adhesive residue to a thickness of approx. 0.5 mm
 Remove residual adhesive bead only briefly before bonding
Damage to paintwork in body aperture
To ensure long-term corrosion protection, it is absolutely essential to touch up damage to paintwork!
The "BMW Color System" painting handbook forms the basis of these repair instructions and must be observed
without fail.
Touch up damage to paintwork on body aperture with BMW multibase filler.
Grind out scratches in non-visible areas and touch up with BMW multibase filler.
Grind extensive areas of damage down to the bare metal and coat with BMW multibase filler (layer thickness
30... 40 µm).
Hardening time:
 With infrared, at least 10 minutes

 Without infrared for at least 60°C, at least 30 minutes
 Without infrared for at least 20°C, at least 24 hours
If a complete build-up of paint is required in the visible area:
 Tape off primed adhesive flange before applying top coat
IMPORTANT: Observe hardening time of BMW multibase filler otherwise a perfect bond
cannot be guaranteed!
Treatment of adhesive area in body aperture:

Adhesive Treatment
Bonding and sealant for car window glass a. Clean with cleaning agent R2 (sourcing
reference: BMW Parts Department, part
number 83 19 0 417 324)
b. Observe an air drying time of at least 5
2007 BMW 335i
minutes (at least 15 minutes when applied to

residual adhesive bead)
c. Apply paint activator (blue stick) to paint
d. Observe an air drying time of at least 1 minute
(at least 10 minutes when applied to residual
adhesive bead)
IMPORTANT: Do not use Sika remover 208 for cleaning in the adhesive area.
Preparation for installation
Prepare plastic nozzle(s) for shaping adhesive bead (when not using the standard nozzle C), can be cut to size
during the air drying time.
Lay a sample bead of approx. 50 mm; if OK, apply immediately to window glass.
 Interruption must be < 5 seconds (incorrect mixture ratio).
Glue cartridge must be vertical to window glass.
Black ceramic glass impermeable to UV light is located on the peripheral zone of the inside edge of the window
to protect the adhesive bead.
Ceramic glass must not be damaged and must be treated as follows.
Treatment of ceramic glass surface (inside of window):

Adhesive (with part numbers) Treatment
Repair kit: a. Clean with cleaning agent R2 (sourcing
reference: BMW Parts Department, part
 83 19 0 444 141/145 number 83 19 0 417 324)
b. Observe an air drying time of at least 5
Glue cartridge:
minutes
 83 19 0 444 144
c. Apply a thin coating of glass activator
d. Observe an air drying time of at least 2
minutes
Version with inspection glass for vehicle identification number in windscreen only
 Close inspection glass (left bottom) with Sika bonding base VP 206 (part number 83 19 9 407 777*)
*sourcing reference: BMW Parts Service
Except for:
2007 BMW 335i
All US/GB models. In addition, all models or models on which the black I-panel cover means that the body
color can not be seen through the inspection glass.
Adhesive quantities
Approx. 1 1/4 glue cartridges are required to bond the windscreen on the following vehicles:
 7 Series
 5 Series from E60
 X5
 X3
Effect of differing adhesive quantities:

Too little adhesive: Too much adhesive:
 Window glass rests too low in body aperture  Window glass rests too high in body aperture
 Strains/tensions may occur (window glass  Wind noise may occur
breakage)  Strains/tensions may occur (window glass
 Insufficient squeezing of adhesive bead breakage)
(leaking)  Dirt contamination of add-on parts by
emerging adhesive
 Adhesive on uninsulated strainer pressure
lines of aerial(s) (interference of reception)
Spacer buffer (spacer)
Before sticking on new spacer buffers, remove all remaining traces of old spacer buffers completely.
Position of spacer buffers must be observed exactly.
Incorrectly fitted spacer buffers will result in:
 Windscreen glass breakage

 Leakage (if the spacer buffer is in the adhesive area)
 Wind noises
Assembly
To prevent a pressure build-up in the passenger compartment when the doors are closed:
 Open a side window
IMPORTANT: Once the adhesive bead has been applied, the window glass must be installed
2007 BMW 335i
within 7 minutes (depending on air humidity, temperature).
After 7 minutes the adhesive bead forms a skin which can no longer guarantee
a perfect bond.
The general rule is:
To secure the window glass, use only the yellow plastic adhesive tape
(sourcing reference: BMW Parts Department, part number 83 19 9 410 979).
The window glass will slip down if other adhesive tapes are used.
Window glass slippage will result in leaks and wind noises.
Remove adhesive residue immediately with adhesive remover (Sika remover 208, sourcing reference: BMW
Parts Department). Do not press out the window glass again.
Check height of windscreen/rear window with special tool 51 0 010 or 51 3 210 .
Assemble vehicle.
Hardening
The adhesive hardens as it reacts with air humidity (with accelerator also due to mixed-in reaction paste) at
room temperature.
Minimum hardening time (table) is obtained from 22°C and 38 % relative air humidity.
A relative humidity of < 30% significantly slows hardening.
At ambient temperatures above 23°C and 50 % relative air humidity (hot countries), the adhesive open time is
shortened to approx. 5 minutes (skin formation time).
The adhesive hardening process is interrupted completely at ambient temperatures below 5°C. In this event,
there will be no increase in the strength of the bonded connection.
Do not subject the vehicle to load on one side during the minimum hardening time (see table, without front
passenger airbag), such as e.g.:
 one wheel on curb

 vehicle hoist
 etc.
Maneuvering inside garage/workshop:

2007 BMW 335i
 only permitted on level ground

 do not under any circumstances drive over approach ramps, e.g. into multistory parking structures
Remove adhesive tapes after hardening time.
If you fail to adhere to the minimum hardening times (see table, without front passenger airbag):
 Leaks and/or wind noises may occur at the window glass
Minimum hardening time:

Minimum hardening time Minimum hardening time "with
"without front passenger front passenger
airbag" (after which vehicle can airbag" (countries where seatbelt
Adhesive be moved) use is not required by law)
Cold processing 1 hour 2 hours(1)
(1) Vehicles with front passenger airbag:
The vehicle can be transferred to the customer after a 1-hour hardening time with the following warning:
Once the windscreen glass has been bonded, all occupants must travel with their seat belts attached
for 1 hour.
This is applicable only for countries where seatbelt use is not required by law.
IMPORTANT: If the minimum hardening time is not adhered to, an accident can cause the
passenger together with the windscreen to fall out of the vehicle after the front
passenger airbag deploys.
Locate leaks:
 by spraying water underneath sealing lips

 with ultrasonic leak detector (sourcing reference: BMW Parts Department)
If necessary, seal leakage with appropriate nozzle.
Version with GPS navigation system 1 (up to 9/97)
After installation of rear window:
 Recalibrate magnetic field probe

 Refer to functional description in ISID (Integrated Service Information Display/Diagnosis and
Information System)
Version with rain sensor, rain/light sensor or rain/light solar sensor

2007 BMW 335i
Remove complete rain sensor, rain/light sensor or rain/light solar sensor, see repair instructions.
After replacing windscreen:
 Initialize rain sensor, rain/light sensor or rain/light solar sensor

 Refer to functional description in ISID (Integrated Service Information Display)
Version with automatic air conditioning
After replacing windscreen:
If condensation sensor is not mounted on new windscreen:
Replace condensation sensor, REFER TO REPAIR INSTRUCTIONS .
Version with Head-Up Display (HUD)
When replacing windscreen in vehicles with rain/light solar sensor , replace this completely: See REPAIR
INSTRUCTIONS .
Before bonding, install windscreen with seal(s) and check HUD; if necessary, press expanding foam tape down
with hand roller.
After bonding windscreen, check and if necessary adjust HUD.
51 31... REMOVING AND INSTALLING/REPLACING RETAINING STRIP FOR COWL PANEL

COVER
 Remove Cover for cowl panel
IMPORTANT: Retaining strip (2) has an aluminium profile insert (1).
Carefully wind out retaining strip (2) (windscreen breakage).
4 Glue bead
5 Pinched butyl
6 Contact surfaces
2007 BMW 335i
Fig. 324: Removal Directions, Aluminium Profile Insert, Glue Bead, Pinched Butyl, Contact
Surfaces And Retaining Strip
Installation:
Clean cutout.
Pay attention to center marking on retaining strip (1) and windscreen.
Insert positioner (2) for retaining strip (1) must be removed after it has been fitted on the windscreen but before
the windscreen itself is installed.
Replacement of retaining strip without windscreen removal:
If adhesive has managed to get onto retaining strip (1), this area must be cut out partially.
To facilitate installation, coat and body cutout with water.
Replacement of retaining strip with removed or new windscreen:
Fit rubber frame (1).
3 Aluminum strip
4 Contact surfaces
5 Butyl
2007 BMW 335i
Fig. 325: Aluminum Strip, Butyl, Positioner, Contact Surfaces, Rubber Frame And Retaining Strip
51 31... REMOVING WINDSCREEN WITH "ROLL OUT 2000"
 51 3 270
Windscreen removal system "Roll Out 2000"

2007 BMW 335i
Fig. 326: Windscreen Removal System Roll Out 2000 Components

NOTE: Using the "Roll Out 2000" system minimizes paintwork and ergonomic damage
as well as damage that is hazardous to health.
WARNING: Follow Safety Instructions for working on cars with airbag systems (risk
of injury).
IMPORTANT: Take care when handling sharp-edged tools and cutting wire (risk of damage to
head airbag).
IMPORTANT: Always keep both suckers dry and clean to ensure their optimum adhesion on
the windscreen.
2007 BMW 335i
Lubricate coil if interlock rattling becomes too loud.
Always wear protective goggles and gloves for your own safety.
Preparatory work:
 To avoid paintwork damage, tape off working area over large area at outlet of wire starter (2) with fabric
adhesive tape (1)
 Cut off required length (A) from cutting wire
(A) = Window diagonal x 4
 Check whether wire can get caught on rivets or retainers; if necessary, insert guide needles in bonding
joint and guide cutting wire past
Fig. 327: Fabric Adhesive Tape And Wire Starter

Pulling cutting wire into car:
 Push wire starter (2) from inside at a suitable point through adhesive bead
 Feed wire end (1) into hole of wire starter (2) and bend back
 Pull in both wires in succession crossways
NOTE: Crossing the wires cuts through the adhesive bead completely.
2007 BMW 335i
Fig. 328: Wire Starter, Wire End And Wire Insertion Direction
Laying cutting wire around windscreen:
 Starting from pull-in point, lay wire eyelet created on the outside counterclockwise around the
windscreen
 Pull excess wire into car interior
IMPORTANT: Make sure the cutting wire is located at all four corner points below the
windscreen.
Check that the cutting wire is not caught on retainers or body.
Secure window on outside with adhesive tape against slipping
Fig. 329: Windscreen And Wire

NOTE: Windows (1) with fitted seals (3) or sprayed-on surrounds:
 Moisten cutting wire (4) and seals (3) on window (1) with water
2007 BMW 335i
 Insert cutting wire (4) in bend (without kinking) between window (1) and
body cutout (2)
Fig. 330: Window, Seals, Cutting Wire, Body Cutout And Removal
Direction
Protecting car interior:
 To avoid damage and if necessary dirt, protect A-pillars, roof and instrument panel by means of parabolic
tool (1) or plastic washer (2)
 Move parabolic tool (1) during removal so that wire cannot get caught
 Always guide plastic washer (2) between wire and panel
Fig. 331: Parabolic Tool And Plastic Washer

Starting removal:
 Place windlass (1) on windscreen

 Feed wire end into coil of windlass (1)
2007 BMW 335i
NOTE: Coil can only be turned in one direction.
 Make sure the wire is always situated in the guide channel of the windlass (1)
 Fit reversible ratchet (2) on coil and tension wire
 Start by cutting lower adhesive bead
 Grip second wire end in special tool 51 3 270
Fig. 332: Reversible Ratchet And Windlass

Moving windlass:
 Before moving windlass, remove reversible ratchet, extension and parabolic tool
 Release sucker on windlass
 Pull and hold black locking button (1)
 Turn windlass and move with sucker
 Refit reversible ratchet, parabolic tool and if necessary extension
 When cutting the corner points, make sure the wire is situated in the guide channel of the windlass; this
makes the cutting job easier
2007 BMW 335i
Fig. 333: Black Locking Button, Windlass Guide Channel And Removal Directions
Installing second windlass:
 Secure second windlass by suction on windscreen

 Feed second wire end into coil
 Cut left side and top left corner point, as described above
 Finish removal
 Remove "Roll Out 2000"
Fig. 334: Installing Second Windlass

Windlass with double coil:
For use with small windows.
 Attach windlass firmly to window so that both coils are turned away from application point of wire
 Feed either the upper wire end into the lower coil or the lower wire end into the upper coil
 Fit reversible ratchet on coil and tension wire
 Cut through approx. 10 cm of bonding joint
2007 BMW 335i
Fig. 335: Windlass With Double Coil

 Feed other wire end into free coil so that the wires cross
 Continue cutting bonding joint by alternately using the coils
 Both wires meet ahead of both coils when removal is completed
Fig. 336: Windlass Wires

51 31... REMOVING WINDSCREEN WITH "ROLL OUT 2000" (CONVERTIBLE)
Windscreen removal system "Roll Out 2000"

2007 BMW 335i
Fig. 337: Identifying Special Tool Kit

NOTE: Both paintwork and ergonomic and health-endangering damage is minimized

with the "Roll Out 2000" system.
Sourcing reference:
See Aftersales Assistance Portal (ASAP) - Service/Technical - Workshop Equipment (Start BMW) - Shop
Workshop Equipment or at www.bmwgroup.com
WARNING: Follow SAFETY INSTRUCTIONS for working on cars with airbag systems
(risk of injury).
IMPORTANT: Take care when handling sharp-edged tools and cutting wire (risk of damage to
head airbag and window glass).
2007 BMW 335i
IMPORTANT: Always keep both suckers dry and clean to ensure their optimum adhesion on
the windscreen.
Lubricate spool if interlock rattling becomes too loud.
Always wear protective goggles and gloves for your own safety.
Mounting suction cup lifters on windscreen or rear window
Fig. 338: Identifying Secure Position Of Suction Cup On Windscreen Or Rear Window
 Secure position of suction cup lifters as shown:

1. Suction cup lifter with double spool
2. Suction cup lifter with single spool
3. Window glass
4. Cutting wire
2007 BMW 335i
Fig. 339: Identifying Secure Position Of Suction Cup On Windscreen Or Rear Window
Preparatory work
 Cut off required length from cutting wire:
Window glass diagonal x 6
 The cutting wire loops must lie on top of each other in area (B).
They must not get caught up in each other. (Otherwise no possibility of cutting the adhesive bead / wire
tears.)
Overlapping of cutting wire loops approx. 10 cm.
Distance from right window edge approx. 30 cm.
Pulling cutting wire into car
 Cut off wire end (1) at an angle and thus pierce adhesive bead (2).
 Wire end must be bent to window glass.
2007 BMW 335i
Fig. 340: Pulling Cutting Wire Into Car

Laying cutting wire around windscreen
 Starting from pull-in point, lay wire eyelet created on the outside around the window glass
 Pull excess wire into car interior
IMPORTANT: Make sure the cutting wire is located at all four corner points below the
windscreen.
Check that the cutting wire is not caught on retainers or body.
Secure window glass on outside with adhesive tape against slipping.
Fig. 341: Laying Cutting Wire Around Windscreen

NOTE: Windows (1) with fitted seals (3) or sprayed-on surrounds:
 Moisten cutting wire (4) and seals (3) on window (1) with water
 Insert cutting wire (4) in bend (without kinking) between window (1) and
body cutout (2)
2007 BMW 335i
Fig. 342: Inserting Cutting Wire In Bend (Without Kinking) Between

Window And Body Cutout
Protecting car interior
 To avoid damage and if necessary dirt, protect A-pillars, roof and instrument panel trim (3) by means of
plastic disc (1)
 Always carry plastic disc (1) between respective wire (2) being strained and trim panel components
Fig. 343: Identifying Protect A-Pillars, Roof And Instrument Panel Trim
Suspending wire in suction cup lifter with double spool
 Insert cutting wire (1) in spool (2) and thereby bend wire
 Insert second wire end in second spool and likewise bend
 Turn spool (2) by hand and wind up loose wire
2007 BMW 335i
Fig. 344: Suspending Wire In Suction Cup Lifter With Double Spool
Starting removal
NOTE: Spool can only be turned in one direction.
 Make sure the wire is always situated in the guide channel of the suction cup lifter (1)
 Fit reversible ratchet on spool (2) and tension wire
 Start by cutting lower adhesive bead
 Both wires meet ahead of both spools when removal is completed
 Remove disc
Fig. 345: Identifying Suction Cup Lifter

51 31... REMOVING WINDOWS WITH AN OSCILLATING KNIFE

2007 BMW 335i
WARNING: Follow safety instructions for working on vehicles with airbag systems
(risk of injury).
IMPORTANT: Handle sharp-edged tools with care (risk of damage to the head airbag and the
window glass).
IMPORTANT: Follow the vehicle-specific repair instructions!
Always wear safety goggles and protective gloves for your own safety.
Cover the working area (side walls, roof-mounted aerial and if necessary
interior equipment) with protective covers.
Tape off body with fabric adhesive tape (e.g. Tesa) in areas where the
oscillating knife could damage the window glass or the paint.
Use suction cups (51 3 010) to lift out the window glass.
Always keep both suction cups dry and clean to ensure their optimum adhesion on the windscreen.
Secure window glass against falling out.
Fig. 346: Lifting Out Window Glass Using Suction Cups 51 3 010
Depending on the area of application, knife 1 or 2 is used.
1. Straight knife with adjustable thrust roller

2. U-shaped knife
Dimension (X) on the knife (1) can be adjusted individually, see vehicle-specific repair instructions.
2007 BMW 335i
NOTE: Sharpen knife blade before every use on a running machine with a grinding
stone (even with new knife blade).
Fig. 347: Identifying Straight Knife With Adjustable Thrust Roller And U-Shaped Knife
Removing from the inside:
Run blade of knife parallel to glass.
Take care not to damage paintwork.
Cut through adhesive bead all the way around.
Pull window glass outwards to remove.
Fig. 348: Removing Window Glass From Inside

2007 BMW 335i
Removal from outside:
Run blade of knife parallel to glass.
Take care not to damage paintwork.
Cut through adhesive bead all the way around.
Pull window glass outwards to remove.
Fig. 349: Removing Window Glass From Outside

Cut through adhesive bead as closely as possible to window glass.
1. Body opening
2. Adhesive bead
3. Knife
4. Window
2007 BMW 335i
Fig. 350: Cutting Through Adhesive Bead As Closely As Possible To Window Glass
51 31... WINDOW GLASS REMOVAL WITH WIRE PULL HANDLE
WARNING: Follow SAFETY INSTRUCTIONS for working on vehicles with airbag

systems (risk of injury).
Always wear safety goggles and protective gloves for your own safety.
Attention! Handle sharp-edged tools with care (risk of damage to the head airbag and the window glass).
Attention! Follow the vehicle-specific repair instructions! Protect inner and outer working area (body, trim
panels, cables etc.) against damage.
Depending on the area of application, a separating cord can also be used as an alternative to wire (Cutting cord,
part number 81 43 2 344 272, refer to BMW Electronic Parts Catalogue).
Using the separating cord prevents any damage to the body.
Do not pull the separating cord over any sharp edges (risk of tearing)!
Use tools:
 Wire pull handle with suction element, part number 81 43 2 326 501, refer to BMW Electronic Parts
Catalogue
 Dashboard protector for vehicle window removal, part number 83 30 2 337 983, refer to BMW Electronic
Parts Catalogue
 Wire starter for window glass disassembly, part number 83 30 2 336 541, refer to BMW Electronic Parts
Catalogue
Use suction cups 51 3 010 to lift out the window glass.

2007 BMW 335i
Always keep both suction cups dry and clean to ensure their optimum adhesion on the windscreen.
Secure window glass (if necessary with adhesive tape) against falling out.
Fig. 351: Lifting Out Window Glass Using Suction Cups 51 3 010
Pulling cutting wire into vehicle:
 Grip wire with pliers (If access is difficult: using wire starter 2 150 267, feed wire through adhesive
bead.)
 Wire end (1) must be bent towards window glass.
 Heat wire end (1) and use it to pierce adhesive bead (2).
 Pull approximately half of the wire into the passenger compartment
NOTE: When using the separating cord, always pull it in using the wire starter 2 150
267.
Fig. 352: Identifying Wire End

2007 BMW 335i
Using wire starter:
Bend wire end approx. 10 mm and insert in notched tip.
Pierce wire starter with uniform pressure through adhesive bead, wire end (bent part) must be positioned on
window glass.
Fig. 353: Using Wire Starter

Attach wire pull handles:
Feed in cutting wire (1) in cutting handle (2) and clamping element (3) as illustrated.
Move back cutting handle (2) over clamping element (3) and trap wire end (4).
WARNING: Danger of injury! Wire end (4) must not protrude out of cutting handle (2).
Cutting handle (2) can be secured with suction cup (5) to the vehicle window or body during each of the work
operations. This prevents damage to the paint.
Fit second wire pull handle to other wire end.

2007 BMW 335i
Fig. 354: Attaching Wire Pull Handles

Perform repair work with the aid of a second person.
Cutting wire (4) must be guided in cutting direction at an acute as possible angle (>45°) to adhesive bead (1).
Cut through adhesive bead (1) by pulling cutting handle (2) and at the same time providing counter support with
cutting handle (3).
Pull back cutting wire (4) with cutting handle (3) and make sure that cutting wire (4) is always held under
tension.
Cut through remaining adhesive bead in the same way.
Fig. 355: Cutting Through Adhesive Bead

51 31 000 REMOVING AND INSTALLING / REPLACING WINDSCREEN

2007 BMW 335i
IMPORTANT: The INSTRUCTIONS FOR WINDOW BONDING serve as the basis for these
repair instructions and must be followed without fail.
51 31 015 REPAIRING DAMAGE TO WINDSCREENS CAUSED BY PITTING (STONE CHIPS)

(CLEAR AND TINTED LAMINATED SAFETY GLASS)
Field of vision (no repairs acceptable):
Fig. 356: Identifying Field Of Vision

A. A 50 mm (gap between field of view / center of vehicle)

B. B Up to end of wiper range, outside (field of view width)
C. C Restriction by wiper range (height of field of view)
IMPORTANT: Repairs must only be carried out outside of the field of vision (refer to Fig. 356).
If the stone chip damage is outside the field of vision, refer to INSTRUCTIONS FOR WINDOW BONDING
51 31 021 REMOVING AND INSTALLING/REPLACING RUBBER FRAME FOR WINDSCREEN
IMPORTANT: Rubber frame (1) features an aluminium section inlay (2).

2007 BMW 335i
Detach adhesive tape (9) between rubber frame (1) and roof outer skin or A-
pillar.
Carefully unwind rubber frame (1) (windscreen breakage).
NOTE: Tear-off lip (5) may be stuck to adhesive (4).
When rubber frame (1) is removed, tear-off lip (5) can tear off and remain in
vehicle.
3 Windscreen
6 Bridge
7 Pinched butyl
8 Sealing lip fitted at side only
9 Adhesive tape
Fig. 357: Rubber Frame, Aluminium Section Inlay, Adhesive Tape, Lip, Windscreen, Bridge, Butyl And
Removal Direction
Replacement of rubber frame without windscreen removal:
Clean cutout.
Detach tear-off lip (5) from rubber frame (1).
If adhesive leaks over tear-off lip (5) at bridge (4), this area must be cut out partially.
To facilitate installation, coat rubber frame (1) and body cutout with water.
Fit rubber frame (1), paying attention to center marking on rubber frame (1) and windscreen.
If necessary, pull liner* off adhesive tape (6) and press rubber frame (1) down firmly on roof outer skin and A-
2007 BMW 335i
pillar.
*Liner is the protective film on the adhesive tape
Fig. 358: Rubber Frame, Tear-Off Lip, Adhesive Tape, Aluminium Strip, Butyl And Bridge
Replacement of rubber frame with removed or new windscreen:
Pay attention to center marking on rubber frame (1) and windscreen.
Fit rubber frame (1) with tear-off lip (5).
2 Aluminium strip
3 Butyl
After installing windscreen, pull liner* off adhesive tape (6) and press rubber frame (1) down firmly on roof
outer skin and A-pillar.
*Liner is the protective film on the adhesive tape
Fig. 359: Rubber Frame, Tear-Off Lip, Adhesive Tape, Aluminium Strip, Butyl And Bridge
2007 BMW 335i
51 31 200 REMOVING AND INSTALLING/REPLACING REAR WINDOW
IMPORTANT: The INSTRUCTIONS FOR WINDOW BONDING serve as the basis for these
repair instructions and must be followed without fail.
51 31 241 REPLACING RUBBER FRAME (TOP/SIDE) FOR REAR WINDOW
Open rear lid.
NOTE: For purposes of clarity, illustrations do not show the rear lid.
IMPORTANT: Rubber frame (1) features an aluminium section inlay (2).
Carefully unwind rubber frame (1) (rear window breakage).
NOTE: Tear-off lip (5) may be stuck to adhesive (4).
When rubber frame (1) is removed, tear-off lip (5) can tear off and remain in
vehicle.
3 Rear window
6 Bridge
7 Pinched butyl
Fig. 360: Rubber Frame, Section Inlay, Tear-Off Lip, Bridge, Adhesive, Pinched Butyl And
Removal Directions
Installation:
Pay attention to center marking on rubber frame (1) and windscreen.

2007 BMW 335i
Replacement of rubber frame without rear window removal:
Detach tear-off lip (3) from rubber frame (1).
If adhesive has managed to get onto bridge (4), this area must be cut out partially.
To facilitate installation, coat rubber frame (1) and body cutout with water.
Replacement of rubber frame with removed or new rear window:
Fit rubber frame (1) with tear-off lip (3).
2 Aluminum strip
5 Butyl
Fig. 361: Rubber Frame, Bridge, Tear-Off Lip, Aluminum Strip And Butyl
FRONT MANUALLY OPERATED WINDOWS

51 32 154 ADJUSTING LEFT OR RIGHT FRONT DOOR WINDOW GLASS (COUPE)
 51 0 320
 51 3 010
 51 3 080
 51 3 300
 51 3 301
 51 3 302
 51 3 310
Prerequisite:
2007 BMW 335i
 Car must stand on its wheels

 Front Door Correct Adjusted To Fit
 Remove Outer Window Cavity Weather Strip
Slacken off screws (1) with special tool 51 3 310 until door window can be moved.
Fig. 362: Screws And Special Tool (51 3 310)

Open door window.
Fit special tool 51 0 320 in front door and press back as far as it will go.
NOTE: Special tool 51 0 320 must rest correctly against door and reach the stop on
guide (1).
Raise the door window.
Fig. 363: Guide, Removal Directions And Special Tool (51 0 320)
2007 BMW 335i
Adjusting retraction depth:
Attach special tool 51 3 080 to door window glass Close front door and door window
NOTE: 2 items of special tool 51 3 080 are required for rapid adjustment of retraction
depths.
Fig. 364: Special Tool (51 3 080) And Door Window Glass
Measure and if necessary adjust retraction depth (C) in areas (A and B).
Retraction depth (C):
A. A = 2.5 ± 0.5 mm
B. B = 3.5 ± 0.5 mm
IMPORTANT: Front door must open and close without the door window glass touching the
roof trim strip.
2007 BMW 335i
Fig. 365: Retractor Depth, Areas A, B And C

Attach special tool 51 3 010 to door window (1).
Slide door window (1) against special tool 51 0 320 .
Adjust retraction depth of door window (1) in area of A and B-pillar.
NOTE: The door window must rest against special tool 51 0 320 while adjusting the
retraction depth.
Special tool 51 0 320 serves as a stop in longitudinal direction.
Fig. 366: Door Window, Special Tools (51 3 010) And (51 3 020)
Tighten screws (1) with special tool 51 3 310.
For tightening torque refer to 51 32 1AZ. in 51 32 FRONT DOOR WINDOWS
Remove special tool 51 3 010 from door window glass.
Open door window and remove special tool 51 0 320.

2007 BMW 335i
Fig. 367: Screws, Special Tool (51 0 320), (51 3 010) And (51 3 310)
NOTE: Top edge of door window (1) must be adjusted parallel to contour (2) of water
drain.
Fig. 368: Door Window, Water drain Contour And Edge

Ideal adjustment, pretension:
Close door until lock closes in first catch.
In this door position, top edge of door window glass (1) must rest on door seal (2).
It must be possible to pull out the paper strip with moderate friction resistance.
2007 BMW 335i
Fig. 369: Door Window Glass, Door Seal And Resting Direction
Adjusting pretension:
NOTE: Note positioning aid on special tool.
Slacken nut (3) with reversing ratchet (2) of special tool 51 3 300 (consisting of 51 3 301 and 51 3 302 ).
Turn the knob (1) on the special tool 51 3 300 to turn the stud (4) and thereby alter the pretension.
Tighten nut (3).
For tightening torque refer to 51 33 1AZ. in 51 33 POWER WINDOWS, FRONT
Check adjustment, repeat procedure if necessary.
NOTE: After completing adjustment work, it is essential to Initialize the power window
unit.
Fig. 370: Knob, Stud, Nut, Reversing Ratchet And Special Tool (51 3 300)
2007 BMW 335i
51 32 154 ADJUSTING LEFT OR RIGHT FRONT DOOR WINDOW GLASS (CONVERTIBLE)
Prerequisite:
 Vehicle must be standing on its wheels on a level floor

 Front door correctly ADJUSTED to fit
 If necessary, close retractable hardtop
IMPORTANT: When closing, the door window glass must not jam on the trim strip in any area
of the window (window glass breakage).
If necessary, incoming check:
The following incoming check must be carried out prior to every adjustment operation:
NOTE: Incoming check is carried out with the window cavity cover strip fitted.
 Denormalize POWER WINDOW

 Measure retraction depths with 2 special tools 51 3 080
 Insert adapter 51 0 341 (blue) in rotary striker and close rotary striker
 Measure pretension with special tool 51 0 342 (steel tape measure)
 Initialize power windows
 Denormalize POWER WINDOW

 Remove OUTER WINDOW CAVITY COVER STRIP (not for checking pretension)
Ideal adjustment, longitudinal direction:
Open door window.
Fit special tool 51 0 210 (blue) in front door and press back as far as it will go. Tool must rest on the door and
sit without any play in the guide (1) in area (A).
NOTE: Special tool 51 0 211 left or 51 0 212 right

2007 BMW 335i
Fig. 371: Fitting Special Tool 51 0 210

NOTE: 2 items of special tool 51 3 080 are required for adjustment of retraction depths.
Ideal adjustment, retraction depth:
 Open door window

 Attach special tool 51 3 080 to door window glass
 Close front door and door window
 Measure retraction depth

Measure retraction depth (C) in areas (A and B).
Retraction depth (C):
IMPORTANT: Previous sealing system:

2007 BMW 335i
(see Fig. 374)
Black to 01/2009
Silver to 03/2009
New sealing system:
(see Fig. 375)
Black starting 01/2009
Silver starting 03/2009
New sealing system can also be installed as replacement in older vehicles. Visually check which build version is
current.
Fig. 373: Identifying Retraction Depth Of Door Window

IMPORTANT: Previous sealing system:
Front sealing system (1) and rear sealing system (2) cause an unevenness.
A = 4 ± 0.5 mm
Gap between measuring point and triangular mirror section = 30 mm
B = 7.5 ± 0.5 mm
Gap between measuring point and window edge = 90 mm
2007 BMW 335i
Fig. 374: Identifying Front And Rear Sealing (Previous Sealing System)
IMPORTANT: New sealing system:
Front sealing system (1) and rear sealing system (2) form a straight line.
A = 4 ± 0.5 mm
Gap between measuring point and triangular mirror section = 30 mm
B = 9 ± 0.5 mm
Gap between measuring point and window edge = 90 mm
2007 BMW 335i
Fig. 375: Identifying Front And Rear Sealing (New Sealing System)
Mask off special tool 51 3 310 in area A with webbed tape. Place suitable film between tool and glass (risk of
damage to paint finish and glass).
Fig. 376: Identifying Fabric Adhesive Tape On Special Tool (51 3 310)
Adjusting longitudinal direction/retraction depth:
Slacken screws (1) with special tool 51 3 310 until door window glass can be moved.
Fig. 377: Identifying Screws And Special Tool 51 3 310

NOTE: Make sure that the window glass is not glued to support (1) in blue area (A).
2007 BMW 335i
(Increased break-away torque)
Fig. 378: Identifying Window Glass Support Area

Attach special tool 51 3 010 to door window glass (1).
Slide door window glass (1) 51 0 210 up against special tool.
Adjust retraction depth of door window (1) in area of A-pillar and B-pillar.
NOTE: Door window glass must rest against special tool 51 0 210 (longitudinal
adjustment) during adjustment of retraction depth.
Fig. 379: Identifying Window Glass And Special Tools

2007 BMW 335i
Installation:
The specified torque moment (MDE) (see 1AZ in 51 32 FRONT DOOR WINDOWS ) is reduced when using
special tool 51 3 310 . Depending on the torque wrench used, this must be calculated in accordance with the
adjacent overview:
MDE = Torque to be set
MDV = Prescribed torque (without special tool)
lj = Standard adjustment length with adjusting tool
l1 = Effective length of torque wrench
l2 = Inside dimension of adjusting tool
lw = Inside dimension of insertion tool (here lw = 145 mm)
NOTE: If screwing is performed from the inside of the door (removed door trim panel),
the tightening torque to be set (10 Nm without special tool) must be observed.
Fig. 380: Identifying MDE Adjacent Equation

Tighten down screws (1) with special tool 51 3 310 .
Tightening torque: see 1AZ in 51 32 FRONT DOOR WINDOWS .
Remove special tool 51 3 010 from door window glass.
Open door window and remove special tool 51 0 210.

2007 BMW 335i
Fig. 381: Tightening Down Screws

Top edge of door window glass (1) must be adjusted parallel to contour (2) of water drain.
Seals on A-pillar and on retractable hardtop must not be damaged.
When the door window glass is retracted into the seals, the seals must not distorted.
Fig. 382: Locating Top Edge Of Door Window And Contour Of Water Drain
Ideal adjustment, pre-tension:
NOTE: Pretension can be checked with or without window cavity cover strip. Pre-
tension is 1.0 mm less with window cavity cover strip. Magnet in special tool 51
0 341 creates the correct door window glass pre-tension on the seal system for
measurement. No force must be exerted on the door or door window glass
during measurement.
Insert special tool 51 0 341 in rotary striker of door lock and close rotary striker manually. Carefully close door.
2007 BMW 335i
Fig. 383: Identifying Special Tool 51 0 341 In Rotary Striker Of Door Lock
Slide special tool 51 0 342 at distance (B) to door window glass side edge into seal (1) and measure dimension
(A) to outside edge of door window glass (2).
Dimension (A) with window cavity cover strip:
A = 51 ±1 mm
Dimension (A) without window cavity cover strip:
A = 52 ±1 mm
B = 10 mm
Fig. 384: Identifying Dimension (A) On Outside Edge Of Door Window Glass
Adjusting pre-tension:
2007 BMW 335i
Slacken nut (3) with reversible ratchet (2) of special tool 51 3 300 (consisting of 51 3 301, 51 3 303, and 51 3
304).
Turn knob (1) on special tool 51 3 300 to turn stud (4) and thereby alter the pre-tension.
Tighten nut (3).
Check adjustment, repeat procedure if necessary.
Fig. 385: Reset Distance By Turning Knob

NOTE: After completing adjustment work, it is essential to INITIALIZE the power

window regulator.
Checking run-in of door window glass:
Door window glass must strike the inside of the seal.
Check adjustment of REAR SIDE WINDOW, adjusting if necessary.
51 32 170 REMOVING AND INSTALLING / REPLACING DOOR WINDOW GLASS, FRONT LEFT
OR RIGHT
 Remove Outer Window Cavity Weather Strip

 Remove Inner Window Cavity Weather Strip
 Remove Sound Insulation
 Remove Outside Door Handle
2007 BMW 335i
Open door window glass (1) down to distance (A)
A = approx. 335 mm
Fig. 386: Door Window Glass And Distance (A)

IMPORTANT: Disconnect plug connection (1) from power window motor (2) (risk of trapping).
Installation:
Carry out function check on power window unit and anti-trapping protection.
If necessary, Initialize Power Window .
Fig. 387: Plug Connection And Power Window Motor

Release screw (1) over opening on outside handle.
Installation:
2007 BMW 335i
Insert door window glass (4) with clamping plate (2) in mounting (3).
For tightening torque refer to 51 32 1AZ. in 51 32 FRONT DOOR WINDOWS
Fig. 388: Mounting Screw, Door Window Glass, Clamping Plate And Mounting
Slide locking clip (1) in direction of arrow.
Unclip door window glass (3) with plain bearing from power window unit.
Turn door window glass (3) and feed towards top rear out of guide rail (2).
Fig. 389: Locking Clip, Door Window Glass, Guide Rail, And Removal Directions
Installation:
Sliding piece (1) with retaining clip must be correctly located in guide (2).
If necessary, replace defective sliding piece (1).
Clamping plate (3) must be correctly engaged with shim (4) on door window glass (5).
2007 BMW 335i
If necessary, replace defective backing (4).
Fig. 390: Sliding Piece, Guide, Clamping Plate, Door Window Glass And Shim
After installation:
Adjust Door Window Glass.
51 32 211 REPLACING FRONT LEFT OR RIGHT RUBBER GUIDE FOR LEFT OR RIGHT DOOR
WINDOW
IMPORTANT: The "Instructions on fitting window guides" serve as the basis for this repair
 Remove Rear-View Mirror on front door
Pop catch (1) of rubber guide (2) out of door.
Pull rubber guide (2) out of window guide rail and remove.
2007 BMW 335i
Fig. 391: Catch, Rubber Guide And Removal Direction

Installation:
Rubber guide (1) must not be damaged particularly at the corners and at catch (2).
Fig. 392: Rubber Guide And Catch

Installation:
Moisten rubber guide (2) with water before fitting with Approved Anti-Friction Agent.
Raise the door window.
Feed rubber guide (2) from above into window guide rail and door window glass.
Close door window glass and at same time slide rubber guide (2) downwards.
Slide rubber guide (2) downwards fully until it is correctly seated on door.
2007 BMW 335i
Feed catch (1) into door.
Fig. 393: Catch, Rubber Guide And Removal Direction

FRONT ELECTRICALLY OPERATED WINDOWS

51 33... NORMALIZATION OF POWER WINDOW UNITS
NOTE: Normalization must be carried out after the following work:
 Removal or replacement of power window unit or window glass

 Coding/programming of footwell module (or junction box)
The following functions are deactivated after a denormalization:
 Short-stroke function
 Anti-trapping protection
 Toll closing
Normalization/denormalization of the power window units is possible via the diagnosis system under the
following path:
=> Diagnosis
=> Footwell module (or junction box)
=> Control unit functions
=> Footwell module (or junction box)
=> Component activation

2007 BMW 335i
Fig. 394: Identifying Control Unit Functions

51 33 000 REMOVING AND INSTALLING (REPLACING) POWER WINDOW UNIT IN LEFT OR

RIGHT FRONT DOOR
 Remove Door Window Glass
Lever out cover (1) and release nut (2).
Installation:
Nut is tightened down when door window glass is adjusted.
For tightening torque refer to 51 33 1AZ in 51 33 POWER WINDOWS, FRONT .
Fig. 395: Front Door Cover And Release Nut

Release drive cable from clips (1).

2007 BMW 335i
Release nuts (2) and feed out front power window rail (3).
Release nuts (4 and 5) and feed out rear power window rail.
Installation:
Clip drive cable correctly in to clips (1).
Nut (1) must again be correctly covered with adhesive foil.
For tightening torque refer to 51 33 1AZ in 51 33 POWER WINDOWS, FRONT .
Fig. 396: Drive Cable Clips, Nuts And Front Power Window Rail
Replacement:
Release screws (1) and detach flat motor (2).
For tightening torque refer to 67 62 1AZ in 67 62 DRIVES, POWER WINDOWS
Fig. 397: Flat Motor And Screws

2007 BMW 335i
51 33... SLIGHTLY LOOSEN POWER WINDOW REGULATOR TO REMOVE DOOR LOCK IN

LEFT OR RIGHT FRONT DOOR
Notes
NOTE: To remove door lock, move rear section of sound insulation (1) toward center.
 Partly remove SOUND INSULATION FROM FRONT DOOR.

Mark measuring point on window lift rail (1) and inner door panel (2).
Fig. 399: Identifying Measuring Points On Window Lift Rail And Inner Door Panel
Determine distance between window lift rail (1) and inner door panel (2) and note down.
2007 BMW 335i
Fig. 400: Measuring Distance Between Window Lift Rail And Inner Door Panel
Slacken off nut (1) on window lift rail (2).
Installation note:
Nut (1) must again be correctly covered with adhesive film.
Fig. 401: Identifying Window Lift Rail And Nut

Remove dummy plug. Loosen nut (3) with special tool 51 3 300 .
Installation note:
Reset the distance you noted down by turning knob (1) on special tool 51 3 300 .
2007 BMW 335i
Fig. 402: Reset Distance By Turning Knob

Installation note:
Check distance between window lift rail (1) and inner door panel (2), repeat previous setting procedure if
necessary.
Fig. 403: Measuring Distance Between Window Lift Rail And Inner Door Panel
Detach rear part of window regulator at bottom and pull in direction of arrow.
2007 BMW 335i
Fig. 404: Pulling In Direction Of Arrow

NOTE: The door lock can now be guided behind the window lift rail.
Fig. 405: Identifying Door Lock Behind Window Lift Rail

HINGED WINDOW
51 36 047 REPLACING COVER AT REAR LEFT OR RIGHT SIDE WINDOW
 00 9 317

Remove trim:
2007 BMW 335i
Release door seal (1) in area of side window (2).
Heat trim (3) with hot air blower and detach with special tool 00 9 317 from bumper (2).
Fig. 406: Door Seal, Side Window And Trim

Fitting trim:
Pretreat adhesive area of cleaned side window with Sika Cleaner 205.
IMPORTANT: Treat only adhesive area of side window with Sika Cleaner 205.
If Sika Cleaner 205 is applied to the visible area of the side window, this will
create a gleaming lining which suggests a separation of the ceramic layer.
Fit door seal, close door and door window glass.
Pull liner* off trim (1).
Position trim (1) on PVC spray-coating (3) of side window (2) at bottom and align.
Align trim (1) in accordance with measurement (A) parallel to door window glass (4) and stick on.
A = 6.5 ± 1 mm
Press down trim (1) with firm thumb pressure over entire adhesive area.
*Liner is the protective film on adhesive tape.

2007 BMW 335i
Fig. 407: Trim, PVC Spray-Coating, Door Window Glass, Measurement Area And Side Window
51 36 070 REMOVING AND INSTALLING / REPLACING LEFT OR RIGHT REAR SIDE WINDOW
IMPORTANT: The INSTRUCTIONS FOR WINDOW BONDING serve as the basis for this repair
ELECTRICAL POWER WINDOWS, BODY

51 37 000 REMOVING AND INSTALLING COMPLETE REAR LEFT OR RIGHT POWER
WINDOW UNIT (CONVERTIBLE)
WARNING: Power window unit has no anti-trapping mechanism.
 Remove LOWER SECTION OF SIDE TRIM AT REAR

 Remove OUTER WINDOW CAVITY COVER STRIP
Disconnect plug connections on aerial amplifier (1).
Release screws (2) and remove connecting bracket (3).
Tightening torque: 7.6 Nm
Installation:
Ensure seal (4) is correctly seated.

2007 BMW 335i
Fig. 408: Disconnecting Plug Connections On Aerial Amplifier

Move side window into uppermost end position.
Release/feed out cable holders (1).
Lever out cover (2) and slacken bolt underneath.
Release screws (3).
Feed out power window unit completely in upward direction.
Fig. 409: Identifying Lever Out Cover And Screws

Release cable holder (1).

2007 BMW 335i

The basic setting procedure for the power window must be carried out before
installing.
After installation, the power window regulator/side window must be adjusted
with respect to the vehicle body.
Fig. 410: Identifying Plug Connection And Cable Holder

Basic setting of power window:
Check dimension (X) at power window regulator.
If necessary set dimension (X) with special tool 51 2 220 at screw (1).
Measurement (X) = 6 mm
Fig. 411: Checking Dimension (X) At Power Window Regulator

Presettings after fitting power window unit:

2007 BMW 335i
Adjust side window glass (1) in accordance with dimension (A) to body (2).
Measuring points in B-pillar area and release for rear screw connection of side window glass (1).
Dimension (A) = 7 ± 1 mm
Check function.
ADJUST side window glass (1).
Fig. 412: Measuring Points In B-Pillar Area

51 37 154 ADJUSTING REAR LEFT OR RIGHT SIDE WINDOW (CONVERTIBLE)
Prerequisite:
 Vehicle must be standing on its wheels on a level floor

 Door window glass correctly ADJUSTED
 Remove REAR WINDOW CAVITY SEAL

 Open retractable hardtop
 Move side window upwards (close)
Ideal adjustment, transversal direction:
Side window glass (1) must be situated at distance (A) to body (2).
2007 BMW 335i
Distance A = 7±1 mm
Measuring points in B-pillar area and release for rear screw connection of side window glass (1).
Fig. 413: Positioning Side Window Glass

Adjusting transversal direction:
Remove side trim upper section.
Slacken screws (3) and adjust distance (A).
Fig. 414: Measuring Points In B-Pillar Area

Ideal adjustment, longitudinal direction:
Side window glass (1) must be positioned at distance (A) to door window glass (2).
2007 BMW 335i
Measurement (A) = 12 ± 1 mm
Parallelism deviation ± 1 mm.
Side window glass (1) may have a max. underprotrusion (B) to door window glass (2).
Measurement (B) = 2 mm
Fig. 415: Identifying Side Window Glass At Distance

Adjusting longitudinal direction:
Slacken screws (1) with special tool 51 3 310 .
Adjust longitudinal direction by moving side window glass (2).
Fig. 416: Identifying Slacken Screws With Special Tool 51 3 310

2007 BMW 335i
Installation:
The specified torque moment 3.5 Nm (MDE) is reduced when using special tool 51 3 310 . Depending on the
torque wrench used, this must be calculated in accordance with the adjacent overview:
MDE = Torque to be set
MDV = Prescribed torque (without special tool)
lj = Standard adjustment length with adjusting tool
l1 = Effective length of torque wrench
l2 = Inside dimension of adjusting tool
lw = Inside dimension of insertion tool (here lw = 145 mm)
NOTE: If screwing is performed from the inside of the door (removed door trim panel),
the tightening torque to be set (10 Nm without special tool) must be observed.
Fig. 417: Identifying MDE Adjacent Equation

Checking retraction depth:
 Close retractable hardtop

 Open door window
 Attach special tool 51 3 080 to side window glass
 Close side window completely
 Measure retraction depth
NOTE: Two 51 3 080 items of special tool are required for adjustment of retraction
depths.
2007 BMW 335i

Measure retraction depth (A) in areas (1 to 2).
Measurement (A):
(1) = 8 ± 2 mm
(2) = 8 ± 2 mm
If necessary, check or readjust settings on:
 Door WINDOW GLASS

 Side window
Fig. 419: Measuring Retraction Depth In Areas

Ideal adjustment, pre-tension:

2007 BMW 335i
NOTE: Pretension can be checked with or without window cavity cover strip.
Pretension is 1.0 mm greater with window cavity cover strip. Magnet in special
tool 51 0 341 (adapter) creates the correct door window glass pre-tension on the
seal system for measurement. No force must be exerted on the door or door
window glass during measurement.
Insert special tool 51 0 341 (adapter) in rotary striker of door lock and close rotary striker manually. Carefully
close door.
Fig. 420: Identifying Special Tool 51 0 341 In Rotary Striker Of Door Lock
Measure gap (A) between side window glass (1) and inside edge of door window glass (2).
NOTE: Measuring point 10 mm below top edge of window glass.
With window cavity cover strip fitted (front and rear): A = 20 +1 mm
Without window cavity cover strip fitted (rear): A = 19 +1 mm

2007 BMW 335i
Fig. 421: Identifying Gap (A) Between Side Window Glass And Inside Edge Of Door Window Glass
Adjusting pre-tension:
Remove rear window cavity cover strip.
Turn adjusting screw (1) with special tool 51 2 220 (Torx) until correct pretension is reached.
NOTE: With hardtop closed, side window glass (2) must run correctly into hardtop
seals (check only when window cavity cover strip fitted).
Fig. 422: Turning Adjusting Screw Using Special Tool 51 2 220

Checking adjustment:
Open door window and side window.
Close both windows simultaneously and check run-in of side window glass to door window glass.
Close retractable hardtop.
Hardtop seals must not be damaged.
Check run-in of both windows in hardtop seals.
51 37 171 REPLACING REAR LEFT OR RIGHT SIDE WINDOW (CONVERTIBLE)
WARNING: Power window unit has no anti-trapping mechanism.

2007 BMW 335i
 Remove REAR POWER WINDOW UNIT
Release screws (1).
Feed side window glass (2) out of power window unit (3).
Installation:
Adjust REAR SIDE WINDOW.
Fig. 423: Identifying Power Window Unit And Side Window Glass
51 37 240 REMOVING AND INSTALLING OR REPLACING OUTER WINDOW CAVITY COVER

STRIP FOR DOOR WINDOW, REAR LEFT OR RIGHT (CONVERTIBLE)
Open lid for retractable hardtop.
Open door window.
Detach window cavity cover strip (1) at clip (2).
Installation:
If necessary, replace faulty clip (2).
Make sure water drain channels (3) are in correct position.
The weatherstrip (1) in area (A) must be sealed on the inner side with butyl tape.
2007 BMW 335i
Fig. 424: Identifying Weatherstrip In Area On Inner Side

Attach adhesive tape under window cavity cover strip (1) (damage to paintwork).
Starting at the rear, carefully lever weatherstrip (1) out of clips (2) on side panel with special tool 00 9 311 .
IMPORTANT: The weatherstrip (1) can bend when lifted out too far.
Installation:
If one or several clips (2) detach from the vehicle body, they must be replaced.
If necessary, touch up any paintwork damage in the area of the detached clips (2).
Fig. 425: Lever Weatherstrip Out Of Clips On Side Panel

Installation:
2007 BMW 335i
Ensure seal (1) is correctly seated.
Fig. 426: Identifying Seal

51 37 242 REPLACING OUTER WINDOW CAVITY WEATHER STRIP FOR REAR LEFT OR
RIGHT SIDE WINDOW (COUPE)
 00 9 317
IMPORTANT: Window cavity weather strip must be replaced after every removal.
NOTE: Window cavity weather strip (1) is attached with retaining clip (2) to trim strip
(3).
Pull window cavity weather strip (1) in direction of arrow off side window glass.
If necessary, position special tool 00 9 317 on window cavity weather strip (1) and knock off from retaining clip
(2).
Installation:
Make sure clip (2) is correctly seated.

2007 BMW 335i
Fig. 427: Window Cavity Weather Strip, Trim Strip, Retaining Clip And Removal Direction
FRONT DOOR TRIM PANEL WITH ARM REST

51 31... NOTES FOR BONDING SOUND INSULATION (SI), DOORS
IMPORTANT: Do not pull on the sound insulation in jerks (risk of damage)
Work steps for removing and installing sound insulation
 Click on "underlined cross-reference" to display at the end of this document
General
Sound insulation is bonded to the inner door panel.
Bonded sound insulation must not be subjected to load (e.g. leak test) before 5 hours have elapsed.
On-the-job safety
When working with bonding products (adhesive, cleaning agent, etc.):

 Change work clothing contaminated with adhesive immediately.
 Change work clothing contaminated with solvents and swelling agents immediately (keep spare work
clothing on hand).
 Take skin protection measures, provide washing facilities including hot water, use silicone-free skin
creams
 Provide eye douche facilities, change water regularly (once a month).
2007 BMW 335i
Handling adhesive area on inner door panel

Adhesive Cleaning
a. Butyl bead applied to sound insulation with a. Cleaning agent R2
protective film
b. Butyl mini-round profile Ø 3 mm from the Under no circumstances: paint thinning
roller
b. Carry out bonding only after an air drying
c. Butyl round profile Ø 6 mm from the roller
time > or = 1 min. Air drying time may be
omitted if the entire bonding surface is wiped
with a dry cloth
c. After cleaning, the bonding surface may not
be touched with hands or fouled again
Repair in area of sound insulation, door
DOOR SOUND INSULATION REPAIR AREA

Repair in the event of damaged sound insulation or  Cut the butyl rope between the sound
leakage insulation and the inner door panel with a
sharp knife
 After the repair is finished, position a new
butyl rope 3 mm directly on the original
adhesive bead
 Heat the butyl bead with a standard hot air
blower until the butyl rope strings when
touched slightly. Do not damage the sound
insulation in the process
 Press down with special tool 51 0 300 .
Perform this work extremely carefully
because the increased amount of adhesive
requires pressure of > or = 20 N/cm2
(compared to firm thumb pressure ~ 30
N/cm2 )
 Visually check the adhesive bead and its
compression (no capillaries or broken
adhesive bead permitted)
 In the cases mentioned, the complete sound
insulation must be replaced. After removing
the sound insulation, removal all butyl
remnants from the inner door panel. Apply 6
mm butyl rope to new sound insulation
 Press down with special tool 51 0 300 to > or
= 20 N/cm2 compare to firm thumb pressure ~
2007 BMW 335i
30 N/cm2 )
The sound insulation must be bonded watertight below the door lock
 Flat bonding surface required all round

 No bonding in event of moisture (e.g. condensation, etc.)
 Bonding area must not show any traces of adhesion-reducing residues (e.g. separating agents, greases,
oils, paraffins, plastisols, cavity wax, polishing dust residues, etc.)
 Remove the protective film directly before joining (under no circumstances remove earlier, since the
butyl, because of its stickiness, will very quickly pick up adhesion-reducing dirt contaminants)
 The sound insulation must be attached with positional accuracy to the inner door panel, because it is no
longer possible to change the position without damaging the butyl bead
 With repainted areas, the maximum permitted temperature of 90°C may not be exceeded in the area of the
sound insulation. Otherwise, the sound insulation must be removed (and replaced, if necessary).
Expiry date of adhesive
24 months, see label on packaging
Disposal of the cleaning cloth
Cleaning cloths and cleaning agent residues are hazardous waste (see also safety data sheet)
Hazardous waste (see also safety data sheet)
51 41 000 REMOVING AND INSTALLING LEFT OR RIGHT FRONT DOOR TRIM PANEL
 00 9 317
 Remove decorative strip from door trim panel
Driver's side:
 Remove Rocker Switch For Side Window Operation
Passenger side:
 Remove Cover On Door Handle
Driver's side only:

2007 BMW 335i
Release screws (1).
For tightening torque refer to 51 41 1AZ in 51 41 FRONT DOOR TRIM PANEL WITH ARMRESTS .
Fig. 428: Screws (Driver's Side Only)

Passenger side only:
Release screws (1).
For tightening torque refer to 51 41 1AZ in 51 41 FRONT DOOR TRIM PANEL WITH ARMRESTS .
Fig. 429: Screws (Passenger Side Only)

NOTE: Start by unclipping door trim panel (1) at bottom.
Release clips (2) for door trim panel (1) with special tool 00 9 317.
2007 BMW 335i
Fig. 430: Door Trim Panel, Clips And Removal Direction

IMPORTANT: On version with light package, pay attention to fibre-optic waveguide in area of
door mirror.
Carefully unclip door trim panel (2) at top from retainers (1).
Fig. 431: Door Trim Panel, Retainers And Removal Direction

Unhook Bowden cable (1) from door lock (2).
Disconnect all plug connections/cable holders and remove door trim panel.
2007 BMW 335i

Installation:
If necessary, replace faulty clips.
Fit all clips with sealing ring.
Make sure clips are installed in correct position.
1. Grey clip
2. White clip
3. Red clip
Fig. 433: Grey Clip, White Clip And Red Clip

Installation:
After assembling the door trim panel proceed as follows:

2007 BMW 335i
 Open door window.

 Lock with vehicle key.
 Check for ease-of-movement on retaining button linkage
 If necessary, align linkages
51 41 001 REPLACING FRONT LEFT OR RIGHT DOOR TRIM PANEL

 Remove Speaker
 Remove Speaker Cover
 Remove Inside Door Opener
 Remove Armrest
E93 only:
 Remove module for passenger compartment protection
51 41 017 REMOVING AND INSTALLING/REPLACING COVER ON FRONT DOOR HANDLE

(PASSENGER SIDE)
 00 9 317
 Remove Decorative Strip from front door (passenger side)
Lever out cover (1) with special tool 00 9 317.
Fig. 434: Cover, Special Tool (00 9 317) And Removal Direction
2007 BMW 335i
Installation:
Catches (1) of cover (2) must not be damaged.
Fig. 435: Catches And Cover

51 41 018 REPLACING SPEAKER TRIM ON FRONT LEFT OR RIGHT DOOR TRIM PANEL
 Remove Speaker In Door Trim Panel at front
Carefully release speaker trim (1) at catches (2) and remove in outwards direction.
NOTE: Catches (2) are held in position by installed speaker.
Installation:
Make sure catches (2) are in correct position. Speaker trim (1) can only be installed in one position.
2007 BMW 335i
Fig. 436: Speaker Trim And Catches

Installation:
Fig. 437: Speaker Catches

51 41 030 REMOVING AND INSTALLING/REPLACING DECORATIVE STRIP ON FRONT LEFT

OR RIGHT DOOR TRIM PANEL
 00 9 317
Starting at rear, release decorative strip (1) with special tool 00 9 317 from clips (2).
Remove decorative strip (1) towards rear.
Installation:
2007 BMW 335i
Clips (2) on decorative strip (1) must not be damaged.
Fig. 438: Door Trim Panel Decorative Strip, Clips And Special Tool (00 9 317)
Installation:
Released or damaged Hutfix clips (1) must be replaced.
Fig. 439: Door Trim Panel Hutfix Clips

51 48 060 REMOVING AND INSTALLING/REPLACING SOUND INSULATION IN LEFT OR

RIGHT FRONT DOOR
See REMOVING AND INSTALLING/REPLACING SOUND INSULATION IN LEFT OR RIGHT

FRONT DOOR.
51 41 090 REPLACING LIGHT STRIP ON DOOR TRIM PANEL AT FRONT
 Remove LED For Front Door Trim Panel Light

2007 BMW 335i
Handle light strip with care.
Do not knock fibre optic cables.
Position new light strip on door trim panel (2) and mark welding spots (1) to be opened.
Drill out welding spots (1).
NOTE: Only drill down to door trim panel area so as not to damage the contact surface.
Feed light strip out of door trim panel (2).
Remove all remnants of plastic from contact surface of door trim panel (2).
Fig. 440: Door Trim Panel And Welding Spots

Installation:
Carefully feed light strip in area (1) into door trim panel.
Push welding pins (3) through holes into door trim panel and secure with locking washers (2).
Shorten welding pins (3) down to measurement (A).
A = 3 mm
2007 BMW 335i
Fig. 441: Welding Pins, Light Strip Area, Measurement Area And Locking Washers
51 41 241 REMOVING AND INSTALLING/REPLACING COVER FOR ARMREST ON DRIVER

DOOR
 00 9 317
 Remove Rocker Switch For Side Window Operation

 Remove Door Trim Panel
Release lock washers (1) on back of door trim panel (2).
Installation:
Studs for lock washers (1) must not be damaged.
If necessary, replace faulty lock washers (1).

2007 BMW 335i
Fig. 442: Lock Washers And Door Trim Panel

Unclip trim (1) with special tool 00 9 317 in upward direction from retainers (2).
Installation:
If necessary, replace faulty retainers (2).
Fig. 443: Trim, Retainers, Special Tool (00 9 317) And Removal Direction
Installation:

51 41 270 REMOVING AND INSTALLING/REPLACING TRIM ON DOOR POCKET

2007 BMW 335i
 00 9 317
Engage special tool 00 9 317 at side and release catches (1) on trim (2).
Feed trim (2) upwards out of door pocket.
Installation:
Attach trim (2) from above to door pocket.
Align catches (1) on trim (2) to door pocket and secure trim (2) to door pocket.
Fig. 445: Catches, Trim And Special Tool (00 9 317)

Installation:

2007 BMW 335i
SIDE COVERING WITH ARM RESTS

51 43 002 REMOVING AND INSTALLING REAR LEFT OR RIGHT SIDE TRIM PANEL
 00 9 317
IMPORTANT: Risk of damage to fibre optic cable in side trim panel.
Light strip must be replaced if fibre optic cable is damaged.
 Remove Decorative Strip From Side Trim Panel

 Remove Armrest Side Section
 Remove Rear Seat
Detach mucket (1) in area of side trim panel.
For tightening torque refer to 51 43 3AZ in 51 43 SIDE TRIM PANEL WITH ARMRESTS .
Fig. 447: Mucket And Screws

Carefully detach side trim panel (1) with special tool 00 9 317 from retainers (2) and clips (3).
Pull side trim panel (1) inwards only to such an extent that plug connections can be disconnected.
NOTE: Fibre optic cable may break off if side trim panel (1) is pulled too far inwards.
2007 BMW 335i
Fig. 448: Side Trim Panel, Retainers And Clips

NOTE: View from outside through door window.
Carefully detach LED holder (1).
Disconnect plug connections from control unit and speaker and remove side trim panel.
Fig. 449: LED Holder And Removal Direction

Installation:
Lug (1) on side trim panel must be correctly inserted into guide (2) of C-pillar panel.
2007 BMW 335i
Fig. 450: Lug And C-Pillar Panel Guide

Installation:
If necessary, replace faulty nuts (1) and/or retainers (2).
Fig. 451: Nuts And Retainers

Installation:
Fit all clips (1) with sealing ring.

2007 BMW 335i
Fig. 452: Clips

51 43 004 REMOVING AND INSTALLING/REPLACING DECORATIVE STRIP ON LEFT OR

RIGHT SIDE TRIM PANEL
 00 9 317
Starting at front, detach decorative strip (1) with special tool 00 9 317 from clips (2) and remove.
Installation:
Clips (2) on decorative strip (1) must not be damaged.
Fig. 453: Clips, Decorative Strip And Special Tool (00 9 317)
Installation:
Released or damaged Hutfix clips (1) must be replaced.

2007 BMW 335i
Fig. 454: Hutfix Clips

51 43 005 REPLACING REAR LEFT OR RIGHT SIDE TRIM PANEL
 Remove Top Section On Armrest

 Remove speaker
 Remove Speaker Trim
 Remove Belt Handover
 Remove Module For Belt Handover
51 43 012 REMOVING AND INSTALLING/REPLACING REAR LEFT OR RIGHT UPPER SIDE

TRIM SECTION (CONVERTIBLE)
If necessary, open retractable hardtop.
Open lid for retractable hardtop.
Release clips (1).
Lever out protective cap (2) and release screw underneath.
Installation:
If necessary, replace defective clip (1) and protective cap (2).

2007 BMW 335i
Fig. 455: Identifying Defective Clip And Protective Cap

Carefully release upper side trim section (1) at retainers (2) and clip (3) in upward direction.
Disconnect plug connection on aerial amplifier and remove upper side trim section (1).
Installation:
If necessary, replace faulty retainers (2).
Spray area of retainers (2) with cavity sealant.
If necessary, replace faulty clips (3) and associated Hutfix in body.
Upper side trim section (1) must be correctly fed into guides (4).
Fig. 456: Identifying Upper Side Trim Section, Retainers And Clip
Replacement
2007 BMW 335i
Remove aerial . See REMOVING AND INSTALLING/REPLACING EMPTY HOUSING FOR ROOF-
MOUNTED AERIAL/ANTENNA .
51 43 018 REMOVING AND INSTALLING/REPLACING SPEAKER TRIM ON LEFT OR RIGHT

SIDE TRIM PANEL
 Remove Speaker In Side Trim Panel
Carefully release speaker trim (1) at catches (2) and remove in outwards direction.
NOTE: Catches (2) are held in position by installed speaker.
Installation:
Make sure catches (2) are in correct position. Speaker trim (1) can only be installed in one position.
Fig. 457: Speaker Trim And Catches

Installation:

2007 BMW 335i
Fig. 458: Speaker Catches

51 43 034 REMOVING AND INSTALLING/REPLACING REAR LEFT OR RIGHT LOWER SIDE

TRIM SECTION (CONVERTIBLE)
 Remove SIDE TRIM UPPER SECTION

 Remove DECORATIVE STRIP FROM SIDE TRIM PANEL
 Remove REAR SEAT .
Release screws (1).
Release lower side trim section (2) at clips (3).
Feed lower side trim section (2) out of entrance cover strip (4).
Disconnect all associated plug connections/cable holders and remove lower side trim section (2) in inward
direction.
2007 BMW 335i
Fig. 459: Identifying Lower Side Trim Section Of Entrance Cover Strip
Installation:
If necessary, replace faulty clips (1 and 2).
Fit all clips (1) with sealing ring.
Make sure clips (1 and 2) are in correct installation position.
1. White clip
2. Blue clip
Fig. 460: Identifying Sealing Ring Clips

Replacement
 Release retaining rings (1) and remove sound insulation (2).

 If necessary, remove MODULE FOR PASSENGER COMPARTMENT PROTECTION (3).
 Remove SPEAKERS (4).
 If necessary, remove LED .
 Remove TOP SECTION ON ARMREST
2007 BMW 335i
Fig. 461: Identifying Retaining Rings And Sound Insulation

51 43 063 REMOVING AND INSTALLING/REPLACING UPPER SECTION ON REAR LEFT OR

RIGHT ARMREST
 00 9 317
Unclip trim (1) upwards with special tool 00 9 317 .
Fig. 462: Trim, Special Tool (00 9 317) And Removal Direction
Installation:
Catches (1) on trim (2) are secured with retaining clips (3) in door trim panel.
Catches (1) on trim (2) and retaining clips (3) on door trim panel must not be damaged.
2007 BMW 335i
Fig. 463: Catches, Trim And Retaining Clips

51 43 070 REMOVING AND INSTALLING/REPLACING SIDE TRIM PANEL, FOOTWELL, ON A-

PILLAR, LEFT (DRIVER SIDE)
 Remove Front Entrance Cover Strip (Inside)

 Remove Trim Panel For Pedal Assembly .
Detach mucket (1) in area of side trim panel (2).
Unscrew bolt (3).
Remove hood/bonnet release lever (4) from side trim panel (2).
Fig. 464: Mucket, Trim Panel, Bolt, Hood/Bonnet Release Lever And Removal Direction
Release screw (1).

2007 BMW 335i
Unclip side trim panel (4) in each case in direction of arrow at retaining points (2 and 3).
If necessary, disconnect associated plug connection and remove side trim panel (4).
Fig. 465: Side Trim Panel, Screw, Retaining Points And Removal Direction
Installation:
If necessary, lever out clips (1) remaining in bore.
Position side trim panel (2) preinstalled with clips (1) on associated bores and clip in to place.
Replacement:
Remove Switch For Unlocking Rear Lid .
Fig. 466: Clips And Side Trim Panel

Replacement on right-hand drive up to model year 2005:

2007 BMW 335i
NOTE: Because of altered locators on side trim panel and trim panel for pedals from
model year 2005, the trim panel for pedals must be reworked.
Cut off ribs (1) on trim panel for pedals (2) flat with scalpel.
Fig. 467: Trim Panel Ribs And Pedals

51 43 075 REMOVING AND INSTALLING / REPLACING SIDE TRIM PANEL, FOOTWELL, ON A-

PILLAR, RIGHT
 00 9 317
 Remove Front Entrance Cover Strip (Inside)
Except on E87:
 Remove Trim For Instrument Panel, Bottom Left
Detach mucket (1) in area of side trim panel (2).
Unclip side trim panel (2) with special tool 00 9 317 in direction of arrow at retaining points (3) and remove.
2007 BMW 335i
Fig. 468: Mucket, Side Trim Panel, Retaining Points, Special Tool (00 9 317) And Removal Direction
Installation:
If necessary, lever out clips (1) remaining in bores.
Position side trim panel (2) preinstalled with clips (1) on associated bores and clip in to place.
Fig. 469: Clips And Side Trim Panel

51 43 090 REMOVING AND INSTALLING/REPLACING LIGHT STRIP IN SIDE TRIM PANEL
 Remove Side Trim Panel

 If necessary, remove LED

2007 BMW 335i
Handle light strip with care.
Do not Knock fibre optic cables.
Release locking washers (1) on sound insulation (2) and remove sound insulation (2).
Fig. 470: Locking Washers And Sound Insulation

Position new light strip on side trim panel (2) and mark welding spots (1) to be opened.
Drill out welding spots (1).
NOTE: Only drill down to door trim panel area so as not to damage the contact surface.
Feed light strip out of side trim panel (2).
Remove all remnants of plastic from contact surfaces of side trim panel (2).
Fig. 471: Side Trim Panel And Welding Spots

2007 BMW 335i
Installation:
Carefully feed light strip in area (1) into side trim panel.
Push welding pins (3) through holes into side trim panel and secure with locking washers (2).
Shorten welding pins (3) down to measurement (A).
A = 3 mm
Fig. 472: Welding Pins, Welding Pins, Measurement Area (A) And Locking Washers
51 43 148 REMOVING AND INSTALLING OR REPLACING TRIM ON LEFT OR RIGHT DOOR

PILLAR (TOP)
 Remove rear side trim panel
Lever out cap (1).
Release screw (2) and detach seatbelt strap.
Tightening torque = 36 Nm.
Installation:
Check that spacer bushing (3) and rubber ring (4) are in correct position.
2007 BMW 335i
Fig. 473: Cap, Screw, Spacer Bushing And Rubber Ring

Detach mucket (1) in area of panel (4).
Release panel (4) at clip (2).
Feed out panel (4) in direction of arrow from door pillar.
Feed out seatbelt strap (3) and remove panel (3).
Fig. 474: Mucket, Panel, Clip, Seatbelt Strap And Removal Direction
Installation:
Clip (1) and guide (2) of panel (3) must not be damaged.
2007 BMW 335i
Fig. 475: Clip, Guide And Panel

51 43 201 REMOVING AND INSTALLING OR REPLACING TRIM FOR ROOF PILLAR AT FRONT
(A-PILLAR), LEFT OR RIGHT
 00 9 340
WARNING: Follow Safety Instructions for working on vehicles with airbag systems.
IMPORTANT: Do not use any sharp-edged tools to remove trim (risk of damage to head
airbag).
Unclip protective cap (1) with special tool 00 9 340 and remove.
Fig. 476: Protective Cap And Special Tool (00 9 340)

Detach mucket (1) in area of trim (2).

2007 BMW 335i
Unscrew bolt (3).
Unclip panel (2) at fastening points (4).
Feed out panel (2) from instrument panel (5) and remove.
Fig. 477: Mucket, Trim, Bolt, Fastening Point, Instrument Panel And Removal Directions
Installation:
If necessary, lever out clips (1) remaining in bore.
Make sure guides (3) of panel (2) are correctly seated in associated mountings.
Position panel (2) pre-installed with clips (1) on associated bores and clip in to place.
Fig. 478: Clips, Guides And Panel

2007 BMW 335i
51 43 251 REMOVING AND INSTALLING/REPLACING TRIM PANEL FOR LEFT OR RIGHT

REAR ROOF PILLAR (C-PILLAR)
WARNING: Follow Safety instructions for working on vehicles with airbag systems.
Disconnect Battery.
IMPORTANT: Do not use any sharp-edged tools to remove trim (risk of damage to head
airbag).
Lever out cap (1) and release screw underneath.
Release panel (2) from clips (3) and feed out in direction of arrow.
Fig. 479: Cap, Panel, Clips And Removal Direction

Installation:
Clips (1) and guides (2) must not be damaged.

2007 BMW 335i
Fig. 480: Clips And Guides

Installation:
Panel for roof pillar must be correctly positioned in guides (1 and 2).
Fig. 481: Roof Pillar Panel Guides

ROOF TRIM PANEL

51 44 001 REMOVING AND INSTALLING/REPLACING HEADLINER (WITHOUT SLIDE/TILT
SUNROOF) (COUPE)
Except for the steps relating to the slide/tilt sunroof, the work is identical to:
Removing And Installing/Replacing Headliner (With Slide/Tilt Sunroof)
51 44 011 REMOVING AND INSTALLING / REPLACING ROOFLINER (WITH SLIDE/TILT

SUNROOF) (COUPE)
2007 BMW 335i
 00 9 321
 Remove Sun Visors And Counter Supports on left/right

 If necessary, remove both Mirror Lights
 Remove ceiling light (front)
 Remove Trim Panels For Roof Pillar at front (A-pillar) left/right
 Remove front Handles
 Remove Trim Panels For Door Pillar at left/right (B-pillar)
 Remove Trim Panels For Roof Pillar at rear (C-pillar) left/right
 Remove ceiling light (rear)
 Remove Trim For Auxiliary Brake Light
 Remove Rear Head Restraints
Open coat hook (1) and release screw (2).
Engage special tool 00 9 321 from left in coat hook (1), lever coat hook (2) out of roofliner and feed out.
Fig. 482: Coat Hook, Release Screw And Special Tool (00 9 321)
IMPORTANT: When removing, do not touch edges of roofliner.
The following tasks must be carried out with a second person assisting:
Move seat backs of both front seats to max. rear position.
Release expander rivets (1).

2007 BMW 335i
Detach roofliner (2) from Velcro-type fasteners (3).
Detach roofliner (2) from clips (4).
Detach mucket (6) towards inside.
Detach mucket (5) from all doors in area of roofliner (2).
Lay roofliner (2) downwards.
Tilt roofliner and remove to front passenger door.
Fig. 483: Roofliner, Expander Rivets, Fasteners, Clips And Muckets

Installation:
Following parts of roofliner must not be damaged or missing:
 Mounting and frame (1) for front mounting bracket

 Wiring harness (2)
 Mounting and frame (3) for rear mounting bracket
 Velcro-type fasteners (4)
 Clips (5).
2007 BMW 335i
Fig. 484: Frame, Wiring Harness, Velcro-Type Fasteners And Clips

Installation:
1. Secure roofliner with mucket

2. Secure roofliner in middle to Velcro-type fastener
3. Snap roofliner in to clips at rear
4. Insert expander rivets at front
5. Screw down grab handles at front on left/right
6. Screw down sun visors and counter supports
7. Add final details to vehicle
51 44 150 REPLACING TRIM FOR FRONT ROOFLINER (CONVERTIBLE)
 Open convertible top or retractable hardtop

 Remove FRONT ROOFLINER/ROOF SWITCH CENTER TRIM INSERT
 Remove both front mirror lights
 Remove both SUN VISORS
 Remove both TRIMS FOR FRONT ROOF PILLAR
E93 only:
Unclip trim (1) on left/right towards top.
Installation:
Replace trim (1).

2007 BMW 335i
Fig. 485: Replacing Trim For Front Roofliner

Detach mucket (1) in area of trim (2).
Pull back trim (2) in direction of arrow and remove.
Installation:
Make sure mucket (1) is correctly seated.
Fig. 486: Detaching Mucket In Area Of Trim

INSTRUMENT CLUSTER TRIM PANEL

51 45... OVERVIEW OF INSTRUMENT PANEL
2007 BMW 335i
Fig. 487: Instrument Panel Components

51 45... REPLACING SIDE COVER ON INSTRUMENT PANEL
 00 9 340
 Pull off mucket of front door in area of cover
Unclip cover (1) with special tool 00 9 340 in direction of arrow from instrument panel trim (2).
2007 BMW 335i
Fig. 488: Instrument Panel Trim, Cover, Special Tool (00 9 340) And Removal Direction
Retaining clips (1) of cover (2) must not be damaged.
Fig. 489: Clips And Cover

51 45... REMOVING AND INSTALLING CARRIER FOR INSTRUMENT PANEL
 Remove INSTRUMENT PANEL TRIM

 Disconnect all necessary cable ties on support tube
 Release wiring harnesses/cable ducts and lay to one side
 If necessary, remove control units/disconnect plug connections
WARNING: To avoid injury, cover holder (1) on support tube (2).

2007 BMW 335i
Fig. 490: Identifying Cover Holder On Support Tube

Detach wiring harness (3) from support tube (2).
Release screws (1) of heater on support tube (2).
Fig. 491: Identifying Wiring Harness, Support Tube And Screws

Release nuts (1) on right and left on support tube (2).

2007 BMW 335i
Fig. 492: Identifying Support Tube And Nuts (Right)

Release screw (1) of heater on support tube (2).
Fig. 493: Identifying Support Tube And Screw

Release screw (1) on support tube (2).

2007 BMW 335i
Fig. 494: Identifying Support Tube And Screw

Release screws (1) on support tube (2) from bracket (3).
Detach support tube (2) with a 2nd person helping and remove.
Fig. 495: Identifying Support Tube, Bracket And Screws

51 45 030 REMOVING AND INSTALLING INSTRUMENT PANEL TRIM
Protection).
 Remove storage compartment

2007 BMW 335i
 Move front seats back completely and lower

 Remove Fixture For Steering Column Stalk
 Remove Both Trims For Front Roof Pillar
 Remove Trim Panel For Pedal Assembly
 Remove Instrument Cluster
 Remove light operator unit
 Remove Decorative Strip On Instrument Panel On Right
 Remove operator unit for heater/air conditioner WITHOUT CCC/ASK or WITH CCC/ASK
 Remove Insert For Radio Control Key
 In appropriate version:
 Remove Radio Receiver
 Remove Audio System Controller
 Remove Car Communication Computer
 If necessary, remove On-Board Monitor

 Remove Right Glovebox With Housing
 Remove Speaker
 If necessary, remove Solar Sensor
2007 BMW 335i
Fig. 496: Screws, Instrument Panel Trim And Removal Direction

Unfasten screws (1 and 3).
Pull back instrument panel trim (2) in direction of arrow.
Disconnect available plug connections and remove instrument panel trim (2).
Installation:
Make sure guides (2) of instrument panel trim (1) are correctly seated in mountings.
Make sure seals are correctly seated on air ducts.
Fig. 497: Instrument Panel Trim And Guides

51 45 031 REPLACING INSTRUMENT PANEL TRIM
 00 9 340
 Remove Instrument Panel Trim
Release screws (1).
Remove center function carrier (2) from instrument panel trim (3).
2007 BMW 335i
Fig. 498: Screws, Centre Function Carrier, Instrument Panel Trim And Removal Direction
Release screws (1).
Remove speaker receptacle (2) from instrument panel trim (3).
Fig. 499: Speaker Receptacle And Instrument Panel Trim

Remove Airbag Module On Passenger Side .
Release screws (1).
Remove holder for airbag module on passenger side (2) from instrument panel trim (3).
2007 BMW 335i
Fig. 500: Screws, Instrument Panel Trim And Passenger Side Airbag Module Holder
Unclip both side fresh-air grills (1) with special tool 00 9 340 in direction of arrow from instrument panel trim
(2).
Unclip cover for steering column opening (3) in direction of arrow from instrument panel trim (2).
Fig. 501: Fresh-Air Grills, Instrument Panel Trim, Steering Column Opening, Special Tool (00 9 340)
And Removal Direction
Remove all metal nuts (2) and clips (3) from instrument panel trim (1).
2007 BMW 335i
Fig. 502: Instrument Panel Trim, Nuts And Clips

51 45 181 REMOVING AND INSTALLING/REPLACING BOTTOM RIGHT TRIM FOR

INSTRUMENT PANEL
NOTE: Move front passenger seat completely towards rear.
Release screws (1).
Feed out trim (2) bottom front.
If necessary, detach plug from footwell light.
Fig. 503: Screws, Bottom Front Trim And Removal Direction

Installation:
Guides (1) on trim (2) must not be damaged.
Replacement:
2007 BMW 335i
If necessary, remove Footwell Light
Fig. 504: Guides And Trim

51 45 185 REMOVING AND INSTALLING/REPLACING PANEL FOR PEDALS
Release screws (1).
Pull back trim for pedal assembly (2).
Disconnect associated plug connections and remove trim for pedal assembly (2).
IMPORTANT: Disconnecting the plug connection for the hands-free system speaker results
in fault memory entries in the telephone control unit (limitation in the
emergency SOS call system).
After fitting, read out fault memory and if necessary delete entries.
Fig. 505: Pedal Assembly And Screws

2007 BMW 335i
Replacement (depending on Security version):
1. Modify Speaker (Park Distance Control)

2. Modify Footwell Light
3. Modify MOST direct access bracket
4. Modify Bluetooth Aerial
5. Cut out opening for clutch pedal
Fig. 506: Speaker, Footwell Light, Clutch Pedal Cut Out, MOST direct Access Bracket And
Bluetooth Aerial
Replacement on right-hand drive up to model year 2005:
NOTE: It is necessary to rework the side trim panel because of modified locators on
the side trim panel and the panel for the pedal assembly from model year 2005.
Remove Side Trim Panel (Driver's Side) .
Cut off the first three upper ribs (1) on side trim panel (2) flat with a scalpel to contact face (3).
2007 BMW 335i
Fig. 507: Upper Ribs, Side Trim Panel And Contact Face
51 45 263 REMOVING AND INSTALLING/REPLACING INSTRUMENT PANEL TRIM ON RIGHT
 00 9 321
Carefully release trim (1) with special tool 00 9 321 from retainers (3) and lock pins (2).
Fig. 508: Trim, Retainers, Special Tool(00 9 321) And Lock Pins
Installation:
Clips (Hutfix) (1) must be seated in associated mountings.
Replace clips (Hutfix) (1) if they were released during removal.
A. A Turn clip (Hutfix) (1) with screwdriver to left by approx. 90°

B. B Lever out clip (Hutfix) (1) from below
2007 BMW 335i
Fig. 509: Clip (Hutfix) Removal Directions

Installation:
Lock pins (1) and retainers (3) on trim (2) must not be damaged.
If necessary, replace lock pins (1) and retainers (3).
Fig. 510: Lock Pins, Retainers And Trim

51 45 370 REMOVING AND INSTALLING (REPLACING) LEFT DECORATIVE STRIP ON

INSTRUMENT PANEL
 00 9 317
Lever out left decorative strip on instrument panel (2) at fastening points (1) with special tool 00 9 317 and
remove in direction of arrow.
Fig. 511: Instrument Panel, Fastening Points, Special Tool (00 9 317) And Removal Direction
2007 BMW 335i
Replacement:
Unlock left fresh-air grill (1) at retaining lugs (2) and remove in direction of arrow from left decorative strip on
instrument panel (3).
Installation:
Make sure left fresh-air grill (1) is correctly seated in mountings (4) of left decorative strip on instrument panel
(3).
Make sure retaining lugs (2) are correctly seated in left decorative strip on instrument panel (3).
Fig. 512: Left Fresh-Air Grill, Retaining Lugs, Instrument Panel, Mountings And Removal Direction
51 45 380 REMOVING AND INSTALLING (REPLACING) RIGHT DECORATIVE STRIP ON

INSTRUMENT PANEL
 00 9 317
Do not turn special tool 00 9 317 when levering out and pay attention to
pressure points.
Lever out right decorative strip (2) from left side beginning at retaining points (1) with special tool 00 9 317 .
Disconnect associated plug connection and remove decorative strip (2).

2007 BMW 335i
Fig. 513: Right Decorative Strip, Retaining Points, Special Tool (00 9 317) And Removal Direction
Installation:
Clips (1) must be seated in associated mountings.
If necessary, remove clips (1) remaining on decorative strip.
Replace damaged clips (1):
A. A Turn clip (1) with screwdriver to left by approx. 90°.

B. B Lever out clip (1) from below.
Fig. 514: Clip removal directions

Replacement:
 Remove Start/Stop Switch

 Remove Switch For Hazard Warning System /central locking
 Remove Right Fresh-Air Grill
2007 BMW 335i
 Remove Center Fresh Air Grill
PARCEL SHELF TRIM PANEL/ ROLLER SUN BLIND

51 46... REMOVING AND INSTALLING/REPLACING COVER FOR REAR LEFT OR RIGHT SEAT
BELT
 Remove Trim Panel On Roof Pillar At Rear
Release clip (1) and screw (2).
Feed luggage compartment wheel arch trim (3) out of rest side section (4) and cover (5).
Fig. 515: Clip, Screw, Luggage Compartment Wheel Arch Trim, Side Section And Cover
Release clips (1) and screw (3).
Slide cover (2) in direction of arrow and feed out of rear parcel shelf (4).
Feed cover (2) out of belt and remove.

2007 BMW 335i
Fig. 516: Clips, Screw, Cover, Rear Parcel Shelf And Removal Direction
51 46 001 REMOVING AND INSTALLING PANEL FOR REAR WINDOW SHELF (PARCEL SHELF)
 Remove left/right Trim Panel For Roof Pillar (C-pillar)

 Remove Rear Mid-Range Speaker on left/right
 Remove all Top Tether Eyelets For Child Seat
 Remove Cover For Seat Belts on left/right
 Remove left/right Armrest Side Sections
Version with roller sun blind:
Release screws (1).
For tightening torque refer to 51 46 3AZ in 51 46 PANEL, REAR PARCEL SHELF, ROLLER SUN
BLIND .
Installation:
Make sure guide pin (2) is correctly seated.

2007 BMW 335i
Fig. 517: Guide Pin And Screws


Remove supports (1).
Release clips (2) and carefully feed out rear parcel shelf (3) towards front.
Installation:
Make sure rear parcel shelf is correctly seated in rear grille.

2007 BMW 335i
Fig. 519: Clips, Supports And Rear Parcel Shelf

51 46 002 REPLACING TRIM FOR ODDMENTS TRAY (BACK SHELF WITH REAR WINDOW
ROLLER BLIND)
Removing and installing/replacing Trim For Oddments Tray (Back Shelf) .
51 46 005 REMOVING AND INSTALLING TRIM FOR ODDMENTS TRAY (BACK SHELF WITH
REAR WINDOW ROLLER BLIND AND THROUGH-LOADING SYSTEM)
51 46 007 REPLACING PANEL FOR REAR WINDOW SHELF (PARCEL SHELF)
 Remove Panel For Rear Window Shelf
Detach counter-plate (1) in direction of arrow from trim (2).
Feed trim (2) out of rear window shelf.

2007 BMW 335i
Fig. 520: Counter-Plate, Trim And Removal Direction

Remove trims (1).
Press roller sun blind (2) together at (A) in direction of arrow and press through from (A) to (B).
Remove roller sun blind (2) towards bottom.
Fig. 521: Trims, Roller Sun Blind, Area (A), Area (B) And Removal Directions
51 46 014 REMOVING AND INSTALLING/REPLACING REAR WINDOW ROLLER BLIND (WITH

THROUGH-LOADING SYSTEM)
51 46 026 REMOVING AND INSTALLING OR REPLACING FRONT AIR OUTLET TRIM GRILLE
(CONVERTIBLE)
2007 BMW 335i
 Remove TRIM COVER ON REAR LEFT/RIGHT ROLLOVER PROTECTION SYSTEM.

 Remove UPPER SECTION OF SIDE TRIM PANEL, LEFT/RIGHT.
 Tilt backrest forwards.
 Open lid for retractable hardtop, fold in retractable hardtop if necessary
Lift trim cover (1) out of retainers (2) with special tool 00 9 323 (scraper) and feed out towards rear.
Installation:
Fig. 522: Lifting Trim Cover Of Retainers With Special Tool 00 9 323
Unclip trim cover (1) on left/right forwards.
Fig. 523: Identifying Trim Cover

2007 BMW 335i
Pull off cover (1) downwards.
Lever out covers (2) and release screws underneath.
Fig. 524: Identifying Lever Out Covers

Release clips (1).
Release screws (2).
Remove seat belts (3) from trim grille (4).
Detach trim grille (4) by lifting upwards.
Installation:
Remove all screws/clips on trim grille (4).
Align trim grille (4) with rollover protection system and secure screws/clips.
2007 BMW 335i
Fig. 525: Identifying Seat Belts, Trim Grille With Clips And Screws
54 62 010 Removing and installing or replacing trim cover on left or right rollbar
 Remove BOTH REAR HEADRESTS .
Undo left/right screws (1) and detach left/right trim panel (2) by lifting upwards.
Fig. 526: Identifying Trim Panel Screws

51 46 050 REMOVING AND INSTALLING/REPLACING TOP TRIM ON REAR APRON (COUPE)
 Remove Luggage Compartment Floor Trim (luggage compartment mat)

2007 BMW 335i
Detach seal (1) in covered area of trim (4).
Lever out protective caps (2) and release screws underneath.
Release expansion rivets (3).
Lever out trim (4) inwards/upwards.
Installation:
If necessary, replace damaged protective caps (2) and expander rivets (3).
Fig. 527: Seal, Trim, Expansion Rivets And Protective Caps

Replacement:
Lift off cover (1).
If necessary, feed out universal holders (2).
Fig. 528: Universal Holders And Cover

2007 BMW 335i
51 46 050 REMOVING AND INSTALLING/REPLACING TOP TRIM ON REAR APRON

(CONVERTIBLE)
 Remove trim for luggage compartment side member on left/right
Release clips (1).
Installation:

Release clips (1).
Release impact plates (2) with special tool 51 2 040 .
Feed out trim (4).
Installation:
Make sure mucket (3) is correctly seated on trim (4).

2007 BMW 335i
Fig. 530: Identifying Impact Plates, Mucket And Clips

FLOOR, LUGGAGE, ENGINE COMPARTMENT TRIM PANELS

51 47... OVERVIEW OF LUGGAGE COMPARTMENT TRIM PANELS
2007 BMW 335i
Fig. 531: Identifying Luggage Compartment Trim Panels Components

51 47... REMOVING AND INSTALLING/REPLACING BATTERY COVER
 Remove LUGGAGE COMPARTMENT TRIM ON SIDE PANEL ON RIGHT
Release clips (1).
Remove battery cover (2).
Installation:
2007 BMW 335i
Make sure battery cover (2) is correctly seated on panel (3).
Fig. 532: Identifying Battery Cover On Panel

51 47... REMOVING AND INSTALLING STORAGE TRAY IN LUGGAGE COMPARTMENT ON

LEFT
Disengage storage tray (1) in upward direction from catches (2) and remove.
Fig. 533: Storage Tray And Catches

51 47... REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT UNDERBODY

PANELLING
Only if removing left underbody panelling:

2007 BMW 335i
 Remove rear Underbody Protection
NOTE: Work shown on 320d by way of example, deviations in detail are possible in
other models.
Release plastic nuts.
Release screws (1, 2 and 3).
Release expansion rivet (4).
Installation:
Replace faulty expander rivets.
Make sure underbody panelling is correctly seated.
Fig. 534: Plastic Nuts, Expansion Rivet And Screws

51 47 000 REMOVING AND INSTALLING/REPLACING FRONT (INSIDE) LEFT OR RIGHT

ENTRANCE COVER STRIP
IMPORTANT: Risk of breakage to connecting lug on B-pillar trim panel. Do not raise entrance
cover strip (1) over entire length simultaneously.
Detach entrance cover strip (1) at clips (2) from front to rear.
Detach entrance cover strip (1) from B-pillar trim panel at bottom in direction of arrow.
If necessary, lever out clips from floor plate.

2007 BMW 335i
Fig. 535: Cover Strip, Clips And Removal Directions

Installation:
Fit entrance cover strip (2) with preinstalled clips (1).
Connecting lug (3) of entrance cover strip (2) must not be damaged.
Fig. 536: Entrance Cover Strip, Clips And Lug

51 75 001 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT UNDERBODY COVER
NOTE: Work shown on E90 by way of example, deviations in detail are possible in
other models.
Release clips (1).
Release screws (2).

2007 BMW 335i
Remove underbody cover (3).
Installation:
Replaced damaged clips (1).
Make sure underbody cover (3) is correctly seated.
Fig. 537: Identifying Underbody Cover With Clips And Screws

51 47 065 REMOVING AND INSTALLING/REPLACING FINISHING STRIP AT FRONT LEFT OR

RIGHT ENTRANCE
 00 9 317
Unclip clips (1) for finishing strip (2) with special tool 00 9 317.
Remove finishing strip (2).

2007 BMW 335i
Fig. 538: Clips, Finishing Strip, Special Tool (00 9 317) And Removal Direction
Installation:
Fig. 539: Finishing Strip Mounting Clips

51 47 101 REMOVING AND INSTALLING/REPLACING LUGGAGE COMPARTMENT FLOOR

TRIM PANEL
Open rear lid.
Remove luggage compartment floor trim (1).
Fig. 540: Luggage Compartment Floor Trim And Removal Direction

51 47 140 REMOVING AND INSTALLING/REPLACING PANEL FOR LUGGAGE COMPARTMENT

PARTITION
2007 BMW 335i
 Remove LUGGAGE COMPARTMENT FLOOR TRIM PANEL
Version with ski bag:
 Remove ski bag
Open lid for lowerable hardtop.
If necessary, extend lowerable hardtop.
Release screw (1).
Release clips (2).
Raise trim (3) slightly and feed out panel (4).
Installation:

51 47 143 REMOVING AND INSTALLING/REPLACING PANEL FOR PASSENGER

COMPARTMENT PARTITION
 Remove rest side section on left/right. See SEATS - REPAIR .
Version with ski bag:

2007 BMW 335i
 Remove trim for ski bag
Pull off cover (1) downwards.
Unclip trims (2).
Release screw (3) and clips (4).
Fig. 542: Identifying Trims, Screw And Clips

Pull panel (1) towards rear and thereby release clips (2) and retainers (3).
Feed out trim (1).
Installation:
If necessary, replace faulty clips (2) and retainers (3).
Fig. 543: Identifying Feed Out Trim With Clips And Retainers
2007 BMW 335i
Installation:
After removal clips can be in position A.
For installation clips must be in position B.
Fig. 544: Identifying Clips In Position A

51 47 151 REMOVING AND INSTALLING/REPLACING LEFT LUGGAGE COMPARTMENT

WHEEL ARCH TRIM
 Remove LUGGAGE COMPARTMENT TRIM ON SIDE PANEL

 Remove LOCATING BRACKET FOR FOLDING ROOF
 If necessary, remove STORAGE TRAY
Release clips (1).
Lever out panel (2) on mucket (3).
NOTE: Do not detach mucket (3) from body.

2007 BMW 335i
Fig. 545: Identifying Lever Out Panel On Mucket And Clips

54 37 232 Removing and installing support block
Move roof module into following intermediate station.
Fig. 546: Moving Roof Module

NOTE: Illustration shows removal of left side.

Lever out expansion rivets (1).
Remove trim (2) for support block.

2007 BMW 335i
Fig. 547: Identifying Expansion Rivets And Trim

Unscrew nuts (1).
Remove support block.
Fig. 548: Identifying Support Block Nuts

NOTE: Observe following work steps for installing support block:
Observe screwing sequence for support block (4).
Turn banjo bolt (2) back.
Tighten nut (1).
Insert banjo bolt lock (2) until contact is made with body.
2007 BMW 335i
Tighten nut (3).
Fig. 549: Identifying Banjo Bolt Lock With Nut

Release screw (1).
Move support element (2) upwards to maximum extent.
Insert screw (1) until contact is made.
It must still be possible to slide the support element (2).
Fig. 550: Moving Support Element Upwards To Maximum Extent

It must still be possible to slide the guide element (2).

2007 BMW 335i
Stow roof module.
Storage element (3) adjusts itself to support height.
Guide element (2) slides into correct position.
Extend roof module until support block is accessible.
Tighten screws (1) and (4).
Fig. 551: Sliding Guide Element

Installation:
Install trim for support block.
51 47 152 REMOVING AND INSTALLING / REPLACING LEFT LUGGAGE COMPARTMENT

WHEEL ARCH TRIM
 Remove Trim On Rear Apron

 Fold down backrest for left rear seat
 If necessary, remove Storage Tray in luggage compartment on left
Lever out socket (1) in direction of arrow and disconnect plug connection.
2007 BMW 335i
Fig. 552: Socket And Removal Direction

Installation:
Guide (1) and catches (2) must not be damaged.
Fig. 553: Guide And Catches

Remove warning triangle (1).
Turn bracket (2) approx. 90° in counterclockwise direction and remove.
Turn bracket (3) approx. 90° in clockwise direction and remove.

2007 BMW 335i
Fig. 554: Warning Triangle, Brackets And Expansion Rivets

Release screw (1) and remove trim (2).
Pull out luggage compartment wheel arch trim (3) in inwards direction.
Installation:
Make sure luggage compartment wheel arch trim (3) is correctly seated on rest side section and side panel.
Fig. 555: Screw, Trim, Luggage Compartment Wheel Arch Trim And Removal Direction
Replacement:
If necessary, release trim (1) at catches (2) from interior and remove rubber pull (3).
2007 BMW 335i
Fig. 556: Trim, Catches And Rubber Pull

51 47 161 REMOVING AND INSTALLING/REPLACING RIGHT LUGGAGE COMPARTMENT

WHEEL ARCH TRIM
 Removing and installing/replacing left luggage compartment wheel arch trim
51 47 162 REMOVING AND INSTALLING / REPLACING RIGHT LUGGAGE COMPARTMENT

WHEEL ARCH TRIM
 Remove Trim On Rear Apron

 Remove Flap In Luggage Compartment Panel
 Fold down backrest for right rear seat
Version with bag holder:
Pull expander rivets (1) out of bag holder (2) and remove bag holder (2).
2007 BMW 335i
Fig. 557: Expander Rivets And Bag Holder

Release clips (1).
Feed out luggage compartment wheel arch trim (4) in direction of arrow.
Installation:
Make sure luggage compartment wheel arch trim (4) is correctly seated on rest side section and side panel.
Fig. 558: Clips, Screw, Cover, Luggage Compartment Wheel Arch Trim And Removal Direction
Replacement:
If necessary, release retainers (1) on back of luggage compartment wheel arch trim (2) and remove securing net
(3).
2007 BMW 335i
Fig. 559: Retainers, Luggage Compartment Wheel Arch Trim And Securing Net
51 47 171 REMOVING AND INSTALLING/REPLACING FLAP IN LUGGAGE COMPARTMENT

TRIM ON RIGHT (COUPE)
Turn fastener (1) 90° to left.
Open flap (2) in luggage compartment trim and remove.
Fig. 560: Flap And Fastener

51 47 171 REMOVING AND INSTALLING/REPLACING FLAP IN LUGGAGE COMPARTMENT

TRIM ON RIGHT (CONVERTIBLE)
Open flap (1) at fastener (2) and remove.

2007 BMW 335i
Fig. 561: Identifying Flap And Fastener

51 47 202 REMOVING AND INSTALLING COVER FOR LUGGAGE COMPARTMENT
Raise cover (1) slightly.
Fig. 562: Identifying Cover And Screws

Installation:
Cover (1) must fit correctly into locators (2) on left and right.
2007 BMW 335i
Fig. 563: Installing Cover In Locators

51 47 203 REMOVING AND INSTALLING/REPLACING TRIM FOR LUGGAGE COMPARTMENT

AT REAR LEFT OR RIGHT
IMPORTANT: Risk of damage to roofliner!

When the trim is removed, the lowerable hardtop must not be stowed in the
luggage compartment.
Tensioning straps can get caught in the hardtop mechanism and tear when the
hardtop is closed.
Turn clip (1) through 90°.
Detach trim (2) in direction of arrow from retainers (2).
Installation:
Clip (1) and retainers (3) must not be damaged.
Fig. 564: Identifying Clip And Retainers

2007 BMW 335i
51 47 205 REMOVING AND INSTALLING/REPLACING PANEL FOR LUGGAGE COMPARTMENT

SIDE MEMBER ON LEFT OR RIGHT
 Remove LUGGAGE COMPARTMENT FLOOR TRIM PANEL

 Remove PANEL FOR MAIN BEARING
 Remove PANEL FOR LUGGAGE COMPARTMENT AT REAR
Left side only
 Version with CD changer:

 Remove LUGGAGE COMPARTMENT SIDE PANEL
 Version without CD changer:

 Remove STORAGE TRAY
Right side only
 Remove BATTERY COVER

 Remove LUGGAGE COMPARTMENT LIGHT
Release clips (1).
Lever out panel (2) from trim (3) and feed out towards inside.
Fig. 565: Identifying Lever Out Panel From Trim And Clips
51 47 207 REMOVING AND INSTALLING/REPLACING PANEL FOR MAIN BEARING ON LEFT

OR RIGHT
2007 BMW 335i
If necessary, close lowerable hardtop.
Slide luggage compartment cover until panel (1) is easily accessible.
Release panel (1) in upward direction from retainers (2) and catches (3).
Fig. 566: Identifying Panel In Upward Direction From Retainers And Catches
Installation:
Following parts of trim (1) must not be damaged or missing:
(2) Clips
(3) Guides
(4) Catch
(5) Retainer
Make sure panel (1) is correctly seated on all retaining elements.

2007 BMW 335i
Fig. 567: Identifying Clips, Guides, Catch And Retainer

51 47 210 REMOVING AND INSTALLING/REPLACING TRUNK TRIM PANEL ON LEFT SIDE

PANEL
 Remove PANEL FOR LUGGAGE COMPARTMENT AT REAR.
Release clip (1) and remove cover.
Fig. 568: Identifying Trunk Trim Panel Cover And Clip

Version with CD changer:
Release clips (1).
Feed out panel (3) on mucket (2).
Release panel (3) at retainers (4) and feed out in upward direction.
2007 BMW 335i
Fig. 569: Identifying Feed Out Panel On Mucket And Clips

Installation:
If necessary, replace faulty clips (1) and retainers (4).
Version without CD changer:
Open flap (1).
Release clips (2).
Fig. 570: Identifying Open Flap And Clips

Release clips (1).

2007 BMW 335i
Feed out panel (3) on mucket (2).
Fig. 571: Identifying Feed Out Panel On Mucket And Clips

Installation:
Lugs (1) of panel (2) must be correctly seated on storage tray (3).
Fig. 572: Identifying Lugs Of Panel On Storage Tray

51 47 220 REMOVING AND INSTALLING/REPLACING LUGGAGE COMPARTMENT TRIM

PANEL ON RIGHT SIDE PANEL
 Remove PANEL FOR LUGGAGE COMPARTMENT AT REAR.

2007 BMW 335i
 Remove FLAP IN LUGGAGE COMPARTMENT PANEL.
Release clip (1) and remove cover (2).
Fig. 573: Identifying Clip And Cover

Release clips (1) and feed out panel (2).

51 47 312 REPLACING FOOTREST FOR FRONT PASSENGER COMPARTMENT
NOTE: Footrest is either bonded to carpet or secured with retaining rings from rear to
carpet.
2007 BMW 335i
 Attachments with retaining rings are drilled out

 Bonded footrest is detached with a hot air blower
The attachment points must always be drilled out first.
Place drilling hole template (1) on footrest (2) and align to outer edge of footrest (2) (see arrows in Fig. 575).
Mark bore holes with punch and remove drilling hole template (1).
Drill out attachment points.
I. Predrill to 3 mm dia.
II. Drill out to 10 mm dia.
NOTE: If the footrest is not bonded, it can be removed now. Continue with the next
work step but one.
Fig. 575: Drilling Hole Template, Arrows And Footrest

Bonded footrest only:
NOTE: Adhesive bead must remain on carpet (risk of damage).
Heat footrest (1) with hot air blower and thereby release adhesive bead from footrest (1).
If necessary, pull off footrest (1) in inward direction.

2007 BMW 335i
Fig. 576: Footrest

Only when fitting retaining rings:
Remove Left Footwell Side Trim Panel .
Drive through pins (1).
Fold carpet (2) inwards slightly and remove pins.
Fig. 577: Pins And Carpet

Installation:
Heat footrest (1) with hot air blower and apply adhesive bead along line (2) with hot-melt adhesive gun.
Place footrest (1) on carpet and stick on.
Press footrest (1) down until adhesive bead has cooled down.
2007 BMW 335i
Fig. 578: Footrest And Dashed Line

51 47 315 REMOVING AND INSTALLING / REPLACING FRONT CARPET FOR PASSENGER

COMPARTMENT

 Remove left/right Front Seat
 Remove Glovebox
 Remove Side Trim Panel In Footwell on left/right
 Remove Accelerator Pedal Module
Version with central bass speaker:
 Remove Central Bass Speaker Trim on left/right
Remove holders (1) towards front.
Pull out air duct (2).

2007 BMW 335i
Fig. 579: Holders, Air Duct And Removal Direction

Cut out carpet (1) at cutting edge (2) on left/right.
Make the cut as far as possible in the direction of the middle of the car to
ensure that the cutting edges are covered by the storage compartment/panels.
Pay attention to cable(s) when cutting.
Fig. 580: Carpet And Cutting Edge

Pay attention to cable(s) when cutting.
Cut out carpet (1) at cutting edge (2).
Guide cable back through carpet (1).
Feed out carpet (1) towards rear/top.

2007 BMW 335i
Fig. 581: Carpet And Cutting Edges

Cutting edges (1) shown on removed carpet (2).
Installation:
Apertures (3) serve as alignment points for fitting the carpet (2).
Replacement:
Place removed carpet on new carpet and carry over cuts to new carpet.
Fig. 582: Cutting Edges, Carpet And Apertures

51 47 440 REMOVING AND INSTALLING/REPLACING REAR CARPET ON SEAT PAN
 Remove left/right Front Seat

2007 BMW 335i
 Remove Handbrake Lever

 Remove Rear Side Trim left/right
 Remove inside Entrance Cover Strip
Version with central bass speaker:
 Remove Central Bass Speaker Trim on left/right
E92 only:
Lever out cap (1).
Release bolt (2).
Tightening torque value = 36 Nm.
Feed out belt and slide bar.
Installation:
Make sure slide bar and grommet are correctly positioned.
Check that spacer bushing (3) and rubber ring (4) are in correct position.
Fig. 583: Spacer Bushing And Rubber Ring

Remove holder (1).
Pull back cable (2) with cable holder (3).
Feed out carpet (4).
Installation:
2007 BMW 335i
Make sure openings for air duct and attachment points are correctly positioned.
Fig. 584: Holder, Carpet, Cable And Cable Holder

51 47 490 REMOVING AND INSTALLING / REPLACING FRONT ASSEMBLY UNDERSIDE

PROTECTION
NOTE: Illustration created using E87 120i as an example. There may be differences in
detail in the case of other models.
Release screws (1).
Pull underbody protection (2) forward under bumper trim (3).
Installation:
Centre underbody protection (2) and tighten down screws (1).
Fig. 585: Underbody Protection, Bumper Trim, Screws And Removal Direction
2007 BMW 335i
Replacement:
 If necessary, modify or replace front section (1) of underbody protection
Fig. 586: Underbody Protection Front Section

51 47 490 REMOVING AND INSTALLING/REPLACING FRONT UNDERBODY PROTECTION

(AWD)
NOTE: Illustration created using 330xi as an example. There may be differences in

detail in the case of other vehicle models.
Remove screws (1 to 4).
Installation
Centre underbody protection (5) and tighten down screws (1 to 4).

2007 BMW 335i
Fig. 587: Identifying Underbody Protection On Bumper Trim With Screws

51 47 491 REMOVING AND INSTALLING/REPLACING REAR UNDERBODY PROTECTION
Single-part underbody protection (without E90/E91/E92 AWD):
Release screws (1).
Pull underbody protection (2) in direction of arrow out of bracket (3).
Installation:
Ensure correct seating.
Fig. 588: Screws, Underbody Protection, Bracket And Removal Direction

Two-part underbody protection
Release screws (1).
Detach underbody protection (2) from bracket (3) and remove.
Installation:

2007 BMW 335i
Fig. 589: Screws, Underbody Protection, Bracket And Removal Direction

Single-part underbody protection (E90/E91/E92 AWD):
Release screws (1).
Remove underbody protection (2) downwards.
Installation:
Fig. 590: Screws And Underbody Protection


2007 BMW 335i
other models.
Release clips (1).
Release screws (2).
Remove underbody cover (3).
Installation:
Replaced damaged clips (1).
Make sure underbody cover (3) is correctly seated.
Fig. 591: Identifying Underbody Cover With Screws And Clips

FRONT LID INSULATION LINING

51 48...NOTES FOR BONDING SOUND INSULATION (SI), DOORS
See NOTES FOR BONDING SOUND INSULATION (SI), DOORS.
51 48 001 REMOVING AND INSTALLING/REPLACING INSULATION LINING ON HOOD
NOTE: Illustration created using the E87 as an example. There may be differences in
Release threaded rivets (1) on insulation lining (2).
Remove insulation lining (2).

2007 BMW 335i
Fig. 592: Threaded Rivets And Insulation Lining

51 48 060 REMOVING AND INSTALLING/REPLACING SOUND INSULATION IN LEFT OR

RIGHT FRONT DOOR
 00 9 317
 Remove Door Trim Panel
If necessary, disconnect plug connection (1).
Using special tool 00 9 317 , lever out sealing bead (2) completely or if necessary partially.
Feed cable (3) out of sound insulation (4) and remove sound insulation (4).
Installation:
Ensure clean bonding and that there are no leaks at sealing bead.
2007 BMW 335i
Fig. 593: Cable, Sound Insulation, Sealing Bead And Plug Connection
Installation:
In case of replacement or partial detachments, lay butylene tape depending on the conditions on inner door
panel or sound insulation.
Seal cable penetrations with butylene tape.
NOTE: Position of butylene tape (1) on sound insulation (2).
Fig. 594: Butylene Tape And Sound Insulation

NOTE: A marking (2) is provided all round on the sound insulation (1).
Butylene tape (3) rests on or inside the marking (2).

2007 BMW 335i
Fig. 595: Marking, Sound Insulation And Butylene Tape

Clean adhesive area on inner door panel with adhesive cleaner.
Air drying time: 1 minute
IMPORTANT: Adhesive areas must be dry and free of dust and grease.
Lay 6 mm dia. butylene tape in a single row in specified adhesive area on acoustic insulation.
Heat butylene tape (hot air blower) and press down firmly on sound insulation all round.
Contact pressure with hand roller: approx. 30 N/cm2
Manual contact pressure: approx. 10 N/cm2
NOTE: Firm thumb pressure has approx. 50 N/cm2
REAR LID TRIM PANEL

51 49... REMOVING AND INSTALLING/REPLACING TRIM FOR REAR LID ON LEFT OR RIGHT
Unfasten clips (1).
Remove trim (2) in direction of arrow.

2007 BMW 335i
Fig. 596: Identifying Cover Clips

51 49 000 REMOVING AND INSTALLING/REPLACING PANEL FOR REAR LID (COUPE)
Version with emergency release:
Detach handle (1) from clip (2).
Disconnect Bowden cable (3) from handle (1).
Installation:
Guide Bowden cable (3) through clip (2) and connect correctly in handle (1).
Fig. 597: Handle, Clip And Bowden Cable

Release clips (1) and remove panel (2).
Installation:
If necessary, replace damaged clips (1).

2007 BMW 335i
Fig. 598: Clips And Panel

51 49 000 REMOVING AND INSTALLING/REPLACING PANEL FOR REAR LID (CONVERTIBLE)
 Remove LUGGAGE COMPARTMENT LIGHT
Release clips (1).
Feed out cover (2) on left/right in direction of arrow.
Fig. 599: Removing Feed Out Cover Clips

Version with emergency release:
Detach handle (1) from clip (2).
Disconnect Bowden cable (3) from handle (1).
Installation:
2007 BMW 335i
Guide Bowden cable (3) through clip (2) and connect correctly in handle (1).
Fig. 600: Identifying Guide Bowden Cable From Handle And Clip
Release screws (1) and remove handle (2).
Remove warning triangle.
Release screws (3) and remove bracket (4).
Fig. 601: Identifying Bracket And Screws

Release clips (1).
Installation:
If necessary, replace damaged clips (1).

2007 BMW 335i
Fig. 602: Identifying Clips


Support rear lid in fully opened position with suitable apparatus.
Release both gas struts (2) on rear lid.
 Push retaining spring (1) to end of gas strut (2).

 Lift out gas strut (2).
Remove trim (3).
Fig. 603: Identifying Retaining Spring And Gas Strut

NOTE: For subsequent work on rear lid, clip gas struts (2) back into place.
REINFORCEMENT, BODY
2007 BMW 335i
51 61... REMOVING AND INSTALLING/REPLACING FRONT ROLLOVER PROTECTION

SYSTEM STRUT (CONVERTIBLE)

Driving without the strut is not permitted!
 Remove backrest. See SEATS - REPAIR .

 Remove PANEL FOR PASSENGER COMPARTMENT PARTITION
Release screws (1).
Angle of rotation: 100°
Release screws (2) and remove strut (3).
Installation:
Replace all screws.
Fig. 604: Identifying Front Rollover Protection System Strut And Screws
51 61... REMOVING AND INSTALLING/REPLACING PROTECTING SKID/MOUNTING

BRACKET (CONVERTIBLE)
2007 BMW 335i
IMPORTANT: Observe SAFETY INSTRUCTIONS for raising the vehicle.

Driving without the protective skid/mounting bracket is not permitted!
 Remove front underbody protection for RWD or AWD
Release screws (1).
Tightening torque: see Fig. 605
Release screw (3).
Tightening torque: see Fig. 605
Release screws (2) and remove protective skid (4).
Installation:
Replace all screws.
Middle lug of protective skid must be situated between mounting bracket and left diagonal strut.
2007 BMW 335i
Fig. 605: Identifying Protective Skid And Screws

Mounting bracket
Gently pull V-struts (1) downwards and remove mounting bracket (2) towards rear.
Installation:
Make sure mounting bracket is correctly positioned.

2007 BMW 335i
Fig. 606: Identifying V-Struts And Mounting Bracket

51 61 011 REMOVING AND INSTALLING/REPLACING V-STRUT, FRONT AXLE CARRIER, LEFT

OR RIGHT (CONVERTIBLE)

Driving without the V-strut is not permitted!
Release screws (1, 2, 3).
Remove V-strut (4) towards front.
Installation:
Replace screws.
Make sure bolts are installed in correct positions.
 Screw (1) M8x55

 Screw (2) M8x35
 Screw (3) M10x35
Tightening torque: see 10 AZ in 51 71 SEALS AND LOOSE BODY PARTS ..

2007 BMW 335i
Fig. 607: Identifying V-Strut And Screws

51 61 017 REMOVING AND INSTALLING/REPLACING DIAGONAL STRUT, FRONT END, LEFT

(CONVERTIBLE)

Only perform work after engine has cooled down.

Driving without the diagonal strut is not permitted!

 If necessary, remove RADIATOR SEAL
 N51, N52, N53: Remove INTAKE FILTER HOUSING
IMPORTANT: Diagonal strut on right side must be installed in direction of travel ahead of
diagonal strut on left side.
Release screws (1) and nuts (2).
Feed out diagonal strut (3) towards top.
Installation:
Replace screws.
Replace self-locking nut.
Nut
2007 BMW 335i
Screw
Fig. 608: Identifying Feed Out Diagonal Strut With Screws And Nuts
51 61 018 REMOVING AND INSTALLING/REPLACING DIAGONAL STRUT, FRONT END, RIGHT

(CONVERTIBLE)



 If necessary, remove RADIATOR SEAL
IMPORTANT: Diagonal strut on right side must be installed in direction of travel ahead of
diagonal strut on left side.
Feed out diagonal strut (3) towards top.

2007 BMW 335i
Installation:
Replace screws.
Nut
Screw
Fig. 609: Identifying Feed Out Diagonal Strut With Screws And Nuts
51 71... REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT SUSPENSION

CROSSBRACE RING
Driving without the suspension cross-brace is not permitted. (Risk of damage

to the body).
 Remove left (or right) SUSPENSION CROSSBRACE.
right side.
2007 BMW 335i
IMPORTANT: It is essential to use the pictured nuts to ensure correct screw-fastening of the
dome cross-brace ring!
Fig. 610: Identifying Nut

Unclip protective cap (1) and disconnect plug connection underneath.
Release nuts (2) and remove suspension crossbrace ring (3).
Installation:
Make sure protective cap (1) is correctly seated.
Replace nuts (2).

2007 BMW 335i
Fig. 611: Identifying Suspension Cross Brace Ring With Protective Cap And Nuts
51 71 371 REMOVING AND INSTALLING/REPLACING TENSION STRUT ON LEFT OR RIGHT

SPRING STRUT DOME
See REMOVING AND INSTALLING/REPLACING TENSION STRUT ON LEFT OR RIGHT SPRING

STRUT DOME.
GASKETS SEALS, LOOSE BODY PARTS

51 71... REMOVING AND INSTALLING/REPLACING COVER FOR CARBON CANISTER
Version, carbon canister, side:
Press thermal insulation (3) to one side slightly and feed out cover (4).
Fig. 612: Screws Thermal Insulation And Cover

Version, carbon canister, middle:

2007 BMW 335i
Fig. 613: Covers And Screws

51 71... REMOVING AND INSTALLING/REPLACING RADIATOR SEAL


NOTE: Prior to removing, pay attention to the exact installation position with respect to
the adjoining components.
Release screws (1).
If necessary, remove underbody protection bracket.
Release catches (2) and feed out radiator seal (3) towards rear.
2007 BMW 335i
Fig. 614: Identifying Catches And Radiator Seal

Installation:
Fig. 615: Identifying Catches

51 71... REMOVING AND INSTALLING/REPLACING LEFT/RIGHT REINFORCEMENT COVER

(COUPE)
Release bolt (1) on front assembly underside protection.
Remove reinforcement cover (2).
Installation:
2007 BMW 335i
Make sure reinforcement cover (2) is correctly seated.
Fig. 616: Bolt, Screws, Nuts And Reinforcement Cover


(CONVERTIBLE)
Installation:
Fig. 617: Identifying Screws And Reinforcement Cover


(AWD)
2007 BMW 335i
Release bolt (1) on front assembly underside protection.
Tightening torque: 2.5-3 Nm.
Installation:
Fig. 618: Identifying Reinforcement Cover With Screws And Nuts (AWD)
51 71... REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT STEERING BOX COVER
 If necessary, remove left or right FRONT WHEEL .
NOTE: Description is shown on the E82 by way of example. There may be differences
in detail in the case of other models.
Prior to removing, pay attention to the exact installation position with respect to
the adjoining components.
The operation is described on the left side; proceed in the same way for the
right side.
NOTE: Spring strut removed for purposes of clarity.
Release screw (1) and plastic nuts (2).
Feed out cover (3) and remove.

2007 BMW 335i
Installation:
Observe NOTES ON FITTING cover (3).
Fig. 619: Identifying Cover With Screw And Nuts

51 71... REMOVING AND INSTALLING/REPLACING MULTIFUNCTION PAN
 Remove Left and Right luggage compartment wheel arch trims
Release screws (1).
Remove guide (2).
Fig. 620: Multifunction Pan Guide And Screws

Release screw (1).

2007 BMW 335i
Fig. 621: Screw

Release screws (1).
Remove cover (2).
Fig. 622: Multifunction Pan Cover And Screws

Release nuts (1) and remove multifunction pan.
For tightening torque refer to 51 71 9AZ in 51 71 SEALS AND LOOSE BODY PARTS .
2007 BMW 335i
Fig. 623: Multifunction Pan Mounting Nuts

Installation:
Seals (1) on multifunction pan (2) must be replaced each time they are removed.
Fig. 624: Seals And Multifunction Pan

51 71... REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT SUSPENSION

CROSSBRACE RING
See REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT SUSPENSION CROSSBRACE

RING.
51 71... REMOVING AND INSTALLING/REPLACING LEFT SPRING SUPPORT PASSAGE COVER

(COUPE)

2007 BMW 335i
 If necessary, remove left FRONT WHEEL .
Release catch (1) and remove cover (2).
Installation:
Catch (1) must not be damaged.
Note correct position of cover (2).

51 71... REMOVING AND INSTALLING/REPLACING RIGHT SPRING SUPPORT PASSAGE

COVER (CONVERTIBLE)
 If necessary, remove right FRONT WHEEL

Release expander rivet (1) and remove cover (2).
Installation:
2007 BMW 335i
If necessary, replace expander rivet (1).
Note correct position of cover (2).
Fig. 626: Identifying Expander Rivet And Cover

51 71... REMOVING AND INSTALLING/REPLACING REAR MIDDLE TENSION STRUT (FROM

03/2007)

Driving without the tension strut is not permitted!
Release bolts (1, 2, 4) and remove tension strut (3).
Installation:
First fasten all bolts provisionally and then tighten down.
 Screw (1) M12x50
 Screw (4) M8x25
2007 BMW 335i
Fig. 627: Identifying Tension Strut And Bolts

IMPORTANT: Rear tension strut must be installed below the right tension strut!
51 71 000 REMOVING AND INSTALLING / REPLACING SEAL ON FRONT DOOR, LEFT OR

RIGHT
NOTE: Work shown on E92 way of example, deviations in detail are possible in other
vehicle models.
Unclip seal (1) in direction of arrow from front door.
Installation:
Make sure seal (1) is correctly seated on window guide (2).
Fig. 628: Front Door Seal, Window Guide And Removal Direction
Installation:
2007 BMW 335i
Clips (1) on seal (2) must not be damaged.
Fig. 629: Clips And Front Door Seal

51 71... NOTES ON FITTING COVERS IN FRONT WHEEL ARCH
IMPORTANT: Make sure all covers in wheel arch are correctly seated in relation to each
other.
E90/E91/E92:
 Panel (1) overlaps cover (2, 3 and 5)

 Cover (2) overlaps cover (3 and 4)
 Cover (4) overlaps cover (3)
Fig. 630: Identifying Panel With Covers (E90/E91/E92)

E93:
2007 BMW 335i
 Panel (1) overlaps cover (2, 3 and 4)

 Cover (3) overlaps cover (4)
Fig. 631: Identifying Panel With Covers (E93)

51 71 038 REMOVING AND INSTALLING/REPLACING FRONT LEFT OR RIGHT WHEEL ARCH

COVER (FRONT SECTION)
 If necessary, remove Front Wheel
other models.
Unscrew nut (3).
Remove wheel arch cover and disconnect plug connection at trigger transmitter.
Installation:
Make sure rear wheel arch cover and air guide (4) are correctly seated.
2007 BMW 335i
Fig. 632: Air Guide, Screws And Nut

Replacement:
Modify covers (1 and 2).
Modify air guide (3).
Version with Tyre Pressure Control:
Modify Trigger Transmitter (4) .
Fig. 633: Covers And Air Guide

Release screws (1).
Remove lower section of cover (2).

2007 BMW 335i
Fig. 634: Cover Lower Section And Screw

51 71 039 REMOVING AND INSTALLING/REPLACING FRONT LEFT OR RIGHT WHEEL ARCH

COVER (REAR SECTION)
 Remove Front Wheel

 If necessary, Remove Reinforcement Cover
other models.
Release screws (1).
Release expander rivets (2).
Unscrew nut (3).
Remove wheel arch cover (4).
Installation:
Ensure wheel arch cover (4) is correctly seated.

2007 BMW 335i
Fig. 635: Screws, Nut, Expander Rivets And Wheel Arch Cover
51 71 041 REMOVING AND INSTALLING/REPLACING REAR LEFT OR RIGHT WHEEL ARCH

COVER
 Remove left/right Rear Wheel
other models.
Release nuts (3) and expander rivet (4).
Carefully feed out wheel arch cover (5) towards bottom.
Installation:
Ensure wheel arch cover (5) is correctly seated.

2007 BMW 335i
Fig. 636: Screws, Nuts, Expander Rivet And Wheel Arch Cover
51 71 103 REMOVING AND INSTALLING/REPLACING TOP COOLING AIR GUIDE
Removing and installing/replacing Bar For Retaining Hook
51 71 120 REMOVING AND INSTALLING/REPLACING COWL PANEL SEAL
 Remove MOLDING ON RAIN GUTTER on left/right
right side.
Pull back tab (1) and release screw (2) underneath.
Installation:
Water drainage channel (3) must not be clogged.

2007 BMW 335i
Fig. 637: Identifying Water Drainage Channel With Back Tab And Screw
Detach seal (1) in direction of arrow from window frame.
Installation:
If necessary, moisten seal (1) with water for better fitting.
Fig. 638: Moisten Seal

51 71 345 REMOVING AND INSTALLING/REPLACING LEFT (OR RIGHT) SUSPENSION

CROSSBRACE
IMPORTANT: Driving without the suspension cross-brace is not permitted. (Risk of damage
to the body).
Suspension cross-brace screws must be tightened to torque and then

tightened down with special tool 00 9 120 .
2007 BMW 335i
 Remove lower section of microfilter housing . See MICROFILTER .
right side.
Release screw (1).
Release nuts (2) and remove suspension crossbrace (3).
Installation:
Make sure suspension cross-brace (3) is in correct installation position.
Replace screw (1) and nuts (2).
Tighten down screw (1) and nuts (2) to torque and then to angle of rotation using special tool 00 9 120 .
Tightening torque for screw (1) 51 71 18AZ .
Tightening torque for nuts (2) 51 71 19AZ .
Fig. 639: Identifying Suspension Cross Brace With Mounting Nuts

51 71 348 REMOVING AND INSTALLING/REPLACING SUSPENSION CROSS-BRACE

MOUNTING
IMPORTANT: Driving without the suspension cross-brace is not permitted. (Risk of damage
to the body).
Screws of suspension cross-brace and cross-brace mounting must be
tightened to torque and then tightened down with special tool 00 9 120 .
2007 BMW 335i
 Remove both SUSPENSION CROSSBRACES.
Remove COWL PANEL COVER.
NOTE: Air manifold is shown removed for purposes of clarity.

Release mucket in covered area.
Remove suspension cross-brace mounting with middle heater bulkhead (3).
Installation:
Replace screw (1).
Tighten down screw (1) to torque and then to angle of rotation using special tool 00 9 120 .
Fig. 640: Identifying Middle Heater Bulkhead

Replacement:
 Release studs (1) and feed suspension cross-brace mounting (2) out of middle heater bulkhead (3)
If necessary, release suspension cross-brace grommets (4)
Installation:
Replace studs (1).

2007 BMW 335i
Fig. 641: Identifying Suspension Cross-Brace Grommets


SPRING STRUT DOME
Notes

Driving without the tension strut is not permitted as otherwise the body may be
damaged.
Tension strut screws must be tightened to torque and then tightened down
with special tool 00 9 120 .
Catch (2) and seal (3) of cover (1) must not be damaged.
Even a minimally damaged cover (1) may result in water leaking in; if necessary, replace cover (1).
2007 BMW 335i

NOTE: Two possible versions of cover (1):
A. Turn cover (with notch) approx. 45° counterclockwise

B. Snap out cover (without notch) in upward direction
Remove cover (1) and release screw underneath.
NOTE: Grommet (3) must not be pulled out of bulkhead because this eliminates the
possibility of correct feeding in when installed.
Release screw (1).
Grip grommet (3) and pull out tension strut (2) in direction of arrow.
Fig. 643: Pulling Tension Strut

Installation:
Replace screws.
Carefully feed tension strut (1) into grommet (2).
Tighten down screws to specified torque and then retighten to angle of rotation using special tool 00 9 120 .

2007 BMW 335i
Fig. 644: Identifying Tension Strut And Grommet

51 71 380 REMOVING AND INSTALLING / REPLACING VIBRATION DAMPER
 Remove BATTERY .
Release screws (1) and remove battery carrier (2).
Fig. 645: Identifying Battery Carrier And Screws

Replacement
Release nuts (1) and remove vibration absorber (2) from battery carrier (3).
2007 BMW 335i
Fig. 646: Identifying Vibration Absorber From Battery Carrier And Nuts
51 71 407 REPLACING REAR SPOILER (M)

NOTE: To ensure correct bonding, it is essential to use the adhesive tape shaped parts
developed for the respective rear spoiler.
Removing rear spoiler:
Carefully detach rear spoiler (1) from rear lid with special tool 00 9 318 (assembly wedge) and hot air blower.
Fig. 647: Identifying Rear Spoiler

IMPORTANT: To avoid paintwork damage, make sure markings (1) are only applied to
adhesive tapes.
2007 BMW 335i
Carry over markings (1) from bottom to top of rear spoiler.
Fig. 648: Identifying Markings

Aligning rear spoiler for installation:
Fig. 649: Aligning Rear Spoiler For Installation

Determine center of rear lid.
Mark dimensions (A, B, C, D and E) on adhesive tapes (1) on left and right. Adhesive tapes must not be situated
2007 BMW 335i
on bonding surface of rear spoiler.
DIMENSIONS REFERENCE CHART

Model series A B C D E
E90 250 200 330 332 334
E92 250 200 372 370 361
E82 250 200 371 372 376
Clean bonding surface on rear lid and rear spoiler with spirit.
NOTE: For cleaning, use a fluff-free disposable cloth or a clean cleaning cloth.
Air drying time at least 1 minute.
Fitting rear spoiler:
IMPORTANT: Avoid the creation of bubbles and folds and do not overstretch when attaching
the adhesive tape.
Pull off adhesive tape shaped part (1) from carrier film.
Position adhesive tape shaped part (1) starting from point (A) on front groove (2) and stick on.
Repeat same procedure on other side.
Fig. 650: Identifying Adhesive Tape Shaped Part And Front Groove
NOTE: Groove (2) serves as a limit marker.
NOTE: To enable the liner* to be pulled off, cut only the adhesive tape and not the liner
into lengths on the other side.
Fold back pull-off tabs of shaped parts and of adhesive tape towards rear. In so
doing, make sure adhesive tape is not exposed.
2007 BMW 335i
Position adhesive tape (1) at distance (A) to adhesive tape shaped part (3) on front groove (2) and stick on.
A= 0.5... 2 mm
* Liner is protective film for bonding surface.
Fig. 651: Identifying Adhesive Tape, Adhesive Tape Shaped Part And Front Groove
Align rear spoiler (1) using markings (2) and secure or press down slightly with a 2nd person helping.
Pull off liner using pull-off tabs (3).
Press down rear spoiler (1) firmly with thumbs or back of hands over entire surface, especially the ends.
Remove adhesive tapes, clean rear lid and rear spoiler.
Fig. 652: Identifying Rear Spoiler And Markings

51 71 447 REMOVING AND INSTALLING OR REPLACING PANEL FOR COVER ON LEFT OR

RIGHT SIDE MEMBER

2007 BMW 335i
 Remove Entrance Cover Strip
Release expansion rivets (1) and screws (2).
Fig. 653: Panel Cover Expansion Rivets And Screws

Release screws (1).
Fig. 654: Panel Cover Mounting Screws

Unclip panel (1) at front.
Unclip rear panel (1) from holder (2).
Open door and remove panel (1) in direction of arrow.

2007 BMW 335i
Fig. 655: Panels, Panel Holders And Removal Direction

Installation:
Catches (1) on holder (2) must not be damaged.
Fig. 656: Catches And Holder

Installation:
If necessary, detach holders (1) from body and fit on panel (2).
If necessary, replace faulty holders (1).

2007 BMW 335i
Fig. 657: Holders And Panel

51 71 482 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT TRAILING LINK (ON

REAR AXLE) (UP TO 03/2007)

Release screws (1, 2, 3).
Remove tension strut (4).
Installation:
Replace screw (2).
Make sure screws are installed in correct positions.
 Screw (1) M12x35
Tightening torque: see 25AZ in Fig. 658.
 Screw (2) M12x50
 Screw (3) M10x25

2007 BMW 335i
Fig. 658: Identifying Tension Strut And Screws

IMPORTANT: Left tensions strut (1) must be installed under right tension strut (2).
Fig. 659: Identifying Left And Right Tension Strut Release Clips (1). Release Screws (2). Remove
Underbody Cover (3).

REAR AXLE) (FROM 03/2007)

Left tension strut
Release bolts (1, 3, 4, 5) and remove left tension strut (2).
Installation:
2007 BMW 335i
Replace screw (3).
 Screw (1) M12x35
 Screw (3) M12x50
 Screw (4) M10x25
 Screw (5) M10x25
Fig. 660: Identifying Left Tension Strut Bolts

Right tension strut
NOTE: Remove left tension strut.
Release screws (1, 3) and remove right tension strut (2).

2007 BMW 335i
Installation:
 Screw (1) M12x35
 Screw (3) M10x25
Fig. 661: Identifying Right Tension Strut And Screws

51 71... REMOVING AND INSTALLING/REPLACING REAR MIDDLE TENSION STRUT (UP TO

03/2007)

Release screws (1, 2).
Installation:
2007 BMW 335i
Fig. 662: Identifying Tension Strut And Screws


03/2007)

Release bolts (1, 2, 4) and remove tension strut (3).
Installation:
 Screw (1) M12x50
 Screw (4) M8x25
IMPORTANT: Rear tension strut must be installed below the right tension strut!
2007 BMW 335i
Fig. 663: Identifying Tension Strut And Bolts

MUCKET FOR DOORS

51 70... FITTING SEALS
NOTE: All seals on the vehicle must be removed with the utmost care. Incorrect fitting
may result in among other things wind noises and water ingress, and may
compromise closing and opening comfort.
 The following instructions always apply:
Seals which are attached to the side frame can be removed and fitted as often as desired.
Fig. 664: Identifying Correct Position For Fitting Seals

 Seals must not be damaged or cracked.

 The clamping area must be pressed together by hand to such an extent that rigid attachment to the side
2007 BMW 335i
flange is still possible. The sides of the seal are permitted to touch each other slightly. A fully compressed
seal is not permitted.
 A special tool to press the clamping area together is not needed. Careful fitting by hand is sufficient.
 The seals must always be fitted over their full extent. There is no defined pressing force.
Fig. 665: Identifying Incorrect Position For Fitting Seals

 If seals are repeatedly removed and fitted in the rear lid area, a new seal must be fitted (water ingress in
event of sheet flaws).
 Seals must be checked after fitting for correct seating. If necessary, the seals must be lifted over the
adjacent components with a suitable tool. Adjacent components must not be damaged.
 Seals must be replaced when the metal insert in the seal is visible (corrosion).
 Ensure that the clamping area is smooth.
Fig. 666: Identifying Clamping Area

 Joint seals which are fitted with plastic clips must rest rigidly on the body. Otherwise, the clips or the
2007 BMW 335i
joint seal must be replaced.
Fig. 667: Identifying Joint Seal With Plastic Clips

2007 BMW 335i
BRAKES Brakes - Repair Instructions
BRAKES
Brakes - Repair Instructions
BRAKE TESTING AND BLEEDING

SAFETY INFORMATION FOR WORKING ON VEHICLES WITH AUTOMATIC ENGINE START-
STOP FUNCTION (MSA)
See SAFETY INFORMATION FOR WORKING ON VEHICLES WITH AUTOMATIC ENGINE

START-STOP FUNCTION (MSA) .
34 00... GENERAL INFORMATION
The brake system is one of the most important safety systems on any motor vehicle. It is therefore essential to
act with utmost care when working on the brake system and to follow the instructions below.
General:
 Ensure cleanliness and only use rags which do not lose lint.
 Wash away or vacuum up brake dust, do not clear it away using compressed air. This dust is a health
hazard.
 Do not under any circumstances allow any oil or grease to get into the brake system. This would result in
a complete malfunction of the brake system.
 When cleaning brake components with brake cleaner, do not allow brake cleaner to get into in the brake
system.
 Even the most minute traces of brake cleaner must be avoided.
Brake fluid:
 Replace brake fluid at least every two years.

 Never reuse drained brake fluid.
 Always use BMW-approved brake fluid, refer to BMW Service Operating Fluids .
 Dispose of brake fluid in approved appliances only.
 Do not allow brake fluid to drain into drain pipes, into the outside environment or into unsuitable
facilities. This would create the risk of groundwater contamination since brake fluid is classed as a fluid
that is hazardous to water.
 Do not allow brake fluid to come into contact with paintwork as this will destroy the paint.
 Brake fluid must not be allowed to remain on bare skin too long in order to avoid skin problems. Wash
skin coated with brake fluid with water and soap.
 If brake fluid makes contact with eyes, immediately flush with large quantity of clean water and visit eye
doctor.
Wheel brakes:
2007 BMW 335i
 Brake pads:
Brake pads must be replaced when the warning threshold of the brake pad wear indicator is reached.
Brake pads must always be replaced on both sides of any axle.
The friction surfaces of the brake pads must not come into contact with oil or grease. The brake pads must
be replaced if they are fouled by such substances.
In the case of rotation-dependent brake pads, make sure the arrow marking points in the direction of
rotation of the brake disk for when the vehicle is moving forward. Brake pads with left/right markings
must be fitted on the relevant side of the vehicle.
One-sided angled areas on the brake pads must be located on the disk contact side of the brake caliper for
when the vehicle is moving forward.
 Brake discs:
Brake disks must not be scored or cracked. Furthermore, minimum brake disk thickness , disk runout,
parallelism and surface roughness of the friction surfaces must not exceed or drop below the permitted
values.
Always strip preservative off new parts before installation. With the rear brake discs, also strip
preservative off brake drum on parking brake.
 Always strip preservative off new parts before installation.

 Brake calipers:
Only approved pastes on the basis of glycol must be used for repairs on brake calipers.
All moving parts on the brake caliper must move freely: note grease specifications.
Use only BMW-approved lubricants to grease caliper guides (refer to BMW Service Operating Fluids ).
Brake lines, brake hoses:
 Brake lines and brake hoses must be correctly routed and must not abut with body or components in a
way which would cause chafing.
 To prevent damage, release and tighten brake line couplings with a special brake line wrench only.
 The system must be bled each time any brake lines have been detached.
 All connection points must be checked for leaks.
 Only tighten down brake hoses on the front axle when wheels are in straight-ahead position.
 Close off open connections of brake lines and individual components to prevent dirt from getting into the
brake system.
 When tightening down brake line couplings, observe for tightening torque refer to 34 32 1AZ in 34 32
2007 BMW 335i
BRAKE LINES .
Wheel-slip control system:
The wheel-slip control system is essentially maintenance-free; however the following must be observed:
 When carrying out welding work with electric welding equipment, be sure to disconnect the plug from
the electronic control unit (ignition turned off).
 During painting work, the control unit may be subjected for brief periods to loads of max. 95 °C and for
long periods (approx. 2 hours) to loads of max. 85 °C.
 Terminals must be completely tight on end poles of battery.
 Brake lines on hydraulic unit must not be swapped over: if applicable, mark them prior to disassembly.
On completion of repair work, carry out swap-over test with the DIS diagnosis system.
34 00... GENERAL INFORMATION ON BREAKING-IN NEW BRAKE DISCS / BRAKE PADS
IMPORTANT: After completing work:
 Carry out function check on brake analyzer (test stand) to ensure that the
brakes complies with legal requirements.
 Carry out test braking while driving at low speed; the effectiveness of the
brakes may be reduced during the initial braking operations.
 Exaggerated drastic and continuous braking operations for faster braking
in are not permitted.
 Advise the customer not to perform any wilful drastic braking in the first
200 km after brake replacement.
 Attach mirror tag to interior rearview mirror.
34 00...INSTRUCTIONS FOR BRAKE TESTING FOR E90 / E91 / E92 / 84 (AWD)
Manufacturing period: as of volume production launch
1. Vehicles with manual gearbox and xDrive:
IMPORTANT: Before driving onto the dynamic brake or power analyzer), switch off the Hill
Descent Control (HDC) and keep it switched off while testing the brakes.
The HDC indicator lamp must not light up! It is possible for the HDC indicator
lamp to go out or not to light up even when HDC operation is activated. This
may be because HDC is temporarily unavailable due to high brake temperature.
Do not select a gear and do not accelerate. Otherwise damages occur to the
test stand or vehicle!
2007 BMW 335i
Pressing the accelerator pedal causes the multi-plate clutch in the transfer case to close, even in Neutral.
Consequently the stationary axle is also driven, and the vehicle surges from the analyzer. Because the front and
rear axles are now coupled, the axle to be tested then increases the brake force until the analyzer is shut down.
2. Vehicles with automatic transmission and xDrive:
IMPORTANT: Before driving onto the dynamic brake or power analyzer), switch off the Hill
Descent Control (HDC) and keep it switched off while testing the brakes.
The HDC indicator lamp must not light up!
It is possible for the HDC indicator lamp to go out or not to light up even when
HDC operation is activated. This may be because HDC is temporarily
unavailable due to high brake temperature.
Carry out brake testing with selector lever in N position (Neutral) only.
Do not accelerate when the rollers start up.
During roller operation pressing the accelerator pedal in selector lever position N (Neutral) has no damaging
effect.
Selecting a gear causes the transfer case clutch to close when the analyzer rollers start up. Consequently the
stationary axle is also driven, and the vehicle surges from the analyzer. Because the front and rear axles are now
coupled, the axle to be tested then increases the brake force until the analyzer is shut down.
34 00... TESTING AWD VEHICLES ON DYNAMIC BRAKE AND POWER ANALYZERS (E30, E34,
E46, E53, E83, E60, E61, E90, E91, E92)
NOTE: Running AWD vehicles on dynamic brake analyzers is governed by different

instructions, depending on the vehicle model.
IMPORTANT: Power measurements on single-axle roller dynamometers are generally not

permitted as total failure of the transfer case cannot be ruled out during such
measurements.
In order to test AWD vehicles on dynamic brake analyzers, it is essential to follow various measures in
accordance with the special instructions in Appendices 1 to 5 for the vehicles in question:
1. E30 AWD
2. E34 AWD
3. E46 AWD
4. E53 X5
5. E83 X3
6. E60 / E61 AWD
2007 BMW 335i
7. E90 / E91/ E92 AWD
34 00 050 BLEEDING BRAKE SYSTEM WITH DSC
NOTE: Read and comply with GENERAL INFORMATION.

When replacing or repairing, observe the filling and bleeding instructions for
the following parts:
 Tandem brake master cylinder

 Hydraulic unit
 Components and connecting lines which are fitted between these
assemblies.
Connect bleeder unit with max. 2 bar filling pressure.
A second person is needed to help carry out this work.
Unclip retaining tabs (1).
Pull cover (3) out of guide (2) and remove.
Fig. 1: Identifying Unclip Retaining Tabs, Guide And Cover

Connect DIS.
Select path: Service functions-Chassis/Suspension-Slip control systems-Bleeding procedure.
Connect brake fluid changer to expansion tank and switch on.
IMPORTANT: Check relevant Operating Instructions for each device.

Charging pressure should not exceed 2 bar.
2007 BMW 335i
Fig. 2: Connecting Brake Fluid Changer To Expansion Tank

Always use BMW-approved brake fluids, refer to BRAKE SYSTEM - OPERATING FLUIDS
Fully rinse the brake system
Connect bleeder hose with collecting tray to bleeder valve on rear right brake caliper.
Open bleeder valve and purge until clear, bubble-free brake fluid emerges.
Close bleed valve.
Follow same procedure on rear left, front right and front left wheel brake.
Fig. 3: Locating Bleeder Valve On Rear Right Brake Caliper

Bleeding rear-axle brake circuit
Close bleeder valve.

2007 BMW 335i
Run bleeding routine with DIS with bleeder valve open.
After completing routine, press brake pedal 5 times to floor; clear and bubble-free brake fluid must flow out.
Close bleed valve.
Repeat procedure at rear left.
Fig. 4: Locating Bleeder Valve On Rear Right Brake Caliper

Bleeding front-axle brake circuit
Connect bleeder hose with collecting tray to bleeder valve on front right brake caliper.
After completing routine, press brake pedal 5 times to floor, clear and bubble-free brake fluid must flow out.
Close bleed valve.

2007 BMW 335i
Fig. 5: Connecting Bleeder Hose With Collecting Vessel To Bleeder Valve

Repeat procedure at front left.
Switch off brake fluid changer and remove from expansion tank.
Check brake fluid level.
Close expansion tank.
NOTE: Pay attention to rubber seal (1) in sealing cap.
Fig. 6: Locating Brake Fluid Level Marking (Max)

34 00 009 CHECKING BRAKES ON TEST STAND
 Check tires for damage

 Check tire treads
 Check tire pressure
IMPORTANT: The corresponding system must be deactivated on vehicles equipped with

ASC+T or DSC.
The ASC+T or DSC telltale and warning light must light up in the instrument
cluster!
The brakes must be at normal operating temperature. To do so, gently warm up the brake disks and brake drums
while dry by braking the vehicle several times.
2007 BMW 335i
Fig. 7: Brake Test Stand

IMPORTANT: Only brake test stands (analyzers) with test speeds of 2.5- 6 km/h may be used.
You must follow without fail the guidelines contained in the operating
instructions of the relevant test stand manufacturer.
Failure to do so may result in damage to the vehicle and the system and also
personal injury.
34 00 009 BRAKE TEST ON BRAKE ANALYZER (TEST STAND) (AWD)
NOTE: 1. Check tires for damage

2. Check tire treads
3. Checking tire inflation pressure
Read and comply with INSTRUCTIONS FOR BRAKE TESTING.
You must follow without fail the guidelines contained in the operating instructions of the relevant test stand
manufacturer.
IMPORTANT: Only brake test stands with test speeds of 2.5-6 km/h may be used.
Before driving onto the brake test stand (dynamic brake analyzer), switch off
the Hill Descent Control (HDC) and keep it switched off while testing the
brakes.
The HDC indicator lamp must not light up!
NOTE: It is possible for the HDC indicator lamp to go out or not to light up even when
HDC mode is activated if HDC is temporarily unavailable on account of high
operating temperature.
2007 BMW 335i
 Vehicles with manual transmission and XDrive:
Do not select a gear and do not accelerate.
 Vehicles with automatic transmission and XDrive:
Carry out brake testing with selector lever in N position (Neutral) only.
Do not accelerate when the rollers start up.
Failure to comply with this instruction may result in damage to the test stand or to the vehicle.
Fig. 8: Identifying Brake Test Stand (Parking Brake Function)

34 00... CHECKING BRAKE DISCS
 Remove WHEELS .
Checking thickness difference:
 Measure thickness difference within brake surfaces at 8 point (spread over the circumference) with a
micrometer gauge
 Compare measurement result with SETPOINT VALUE
2007 BMW 335i
Fig. 9: Measuring Brake Surface Thickness Using Micrometer Gauge

Check minimum brake disc thickness:
 Position special tool 34 1 280 at three measuring points in area (1) and measure.
 Compare measurement result and lowest value with SETPOINT VALUE
Fig. 10: Positioning Special Tool (34 1 280) At Three Measuring Points
34 00 010 CHECKING THICKNESS OF BRAKE PAD
NOTE: The thickness of the outer brake pads can be determined without removing the
wheels.
If necessary, move car until opening for brake pad wear indicator (brake pad)
can be seen through rim styling.
Insert special tool 34 1 260 through rim into opening for brake pad wear indicator.
2007 BMW 335i
Press special tool onto brake pad. Slide ring (1) in direction of arrow up to stop and read off measured value.
NOTE: A. Brake disk

B. Brake pad with backplate
Safe limit for lining wear, front brake.
Safe limit for lining wear, rear brake.
Fig. 11: Special Tool (34 1 260), Ring, Brake Disk, Brake Pad And
Measuring Directions
34 00 012 PARKING BRAKE FUNCTION CHECK
IMPORTANT: Follow instructions for BRAKE TESTING ON TEST STAND.
NOTE: If deviations are identified during the following check, the parking brake must
be adjusted:
Drive vehicle onto chassis dynamometer.
Warm up brakes.
Check handbrake.
0th tooth (handbrake released): Vehicles with manual transmission: Shift lever in neutral position.
Vehicles with automatic transmission: Selector lever in "N" position.
 Without locking differential < or = 150 N.

 With locking differential < or = 200 N (possibly odd display).
2007 BMW 335i
1st tooth: No increase in braking force with regard to 0th tooth. Indicator lamp can be lit.
2nd tooth: Indicator lamp must be lit.
3rd tooth: Increase in braking force.
5th tooth: The brake force display must have reached < or = 400 N.
Checking brake force differential at wheel:
Apply handbrake until a wheel circumferential force (measured on brake test stand) of min. 1000 N is reached.
Max. permitted brake force differential right/left < or =35 % (referred to greater brake value).
It must be possible to brake with locked wheels with the handbrake.
34 00 025 REPLACING FLUID IN BRAKE SYSTEM
NOTE: Read and comply with General Information.
IMPORTANT: When carrying out repairs to the brake system, follow the procedure set out in
Bleeding brake system with DSC.
Fig. 12: Retaining Tabs, Cover And Guide

NOTE: Check relevant Operating Instructions for each device.

2007 BMW 335i
Charging pressure should not exceed 2 bar
Fig. 13: Brake Fluid Changer To Expansion Tank And Switch On

Flushing brake system completely
Close bleed valve.
NOTE: The clutch slave cylinder must also be scavenged in vehicles with manual
transmissions.
Fig. 14: Connecting Bleeder Hose With Collecting Tray

2007 BMW 335i
Fig. 15: Locating Brake Fluid Level Mark And Sealing Cap Rubber Seal
34 00 050 BLEEDING BRAKE SYSTEM WITH DSC
When replacing or repairing, observe the filling and bleeding instructions for
the following parts:
 Tandem brake master cylinder

 Hydraulic unit
 Components and connecting lines which are fitted between these
assemblies.
Connect bleeder unit with max. 2 bar filling pressure.
A second person is needed to help carry out this work.

2007 BMW 335i

Connect DIS.
Select path: Service functions - Chassis/Suspension - Slip control systems - Bleeding procedure.
Fig. 17: Connecting Brake Fluid Changer To Expansion Tank

2007 BMW 335i
Close bleed valve.

Bleeding rear-axle brake circuit
After completing routine, press brake pedal 5 times to floor; clear and bubble-free brake fluid must flow out.
Close bleed valve.
Repeat procedure at rear left.

2007 BMW 335i
Bleeding front-axle brake circuit
Connect bleeder hose with collecting tray to bleeder valve on front right brake caliper.
After completing routine, press brake pedal 5 times to floor, clear and bubble-free brake fluid must flow out.
Close bleed valve.
Repeat procedure at front left.
Fig. 20: Bleeding Front-Axle Brake Circuit


2007 BMW 335i
Fig. 21: Brake Fluid Level Mark And Sealing Cap Rubber Seal
34 00 050 REPLACING FLUID IN ABS/ASC+T BRAKE SYSTEM
IMPORTANT: When carrying out repairs to the brake system, follow the procedure set out in
Bleeding brake system with DSC.

NOTE: Check relevant Operating Instructions for each device.

2007 BMW 335i
Charging pressure should not exceed 2 bar
Fig. 23: Brake Fluid Changer To Expansion Tank And Switch On

Close bleed valve.
NOTE: The clutch slave cylinder must also be scavenged in vehicles with manual
transmissions.

2007 BMW 335i
Fig. 25: Locating Brake Fluid Level Mark And Sealing Cap Rubber Seal
34 00 513 CHECKING PARKING BRAKE SETTING (VEHICLE CHECK FOR SERVICE)
IMPORTANT: Follow instructions for Brake testing on test stand.
NOTE: If deviations are identified during the following check, the parking brake must
be adjusted:
Drive vehicle onto chassis dynamometer. Warm up brakes. Check handbrake. 0th tooth (handbrake released):
 Vehicles with manual transmission: Shift lever in neutral position.

 Vehicles with automatic transmission: Selector lever in "N" position.
 Without locking differential =150 N.
 With locking differential = 200 N (possibly odd display).
5th tooth: The brake force display must have reached > or = 400 N.
2007 BMW 335i
Apply handbrake until a wheel circumferential force (measured on brake test stand) of min. 1000 N is reached.
Max. permitted brake force differential right/left =35 % (referred to greater brake value).
FRONT BRAKE
34 11... OVERVIEW OF FRONT BRAKES
Fig. 26: Overview Of Front Brakes

34 11 000 REMOVING AND INSTALLING OR REPLACING BRAKE PADS ON BOTH FRONT DISC
BRAKES (TRW FLOATING CALIPER)
2007 BMW 335i
IMPORTANT: The brake pad wear sensor must be replaced once it has been removed (brake
pad wear sensor loses its retention capability in the brake pad).
 Remove wheels
 Remove brake pad wear sensor
Pull brake pad wear sensor (1) towards rear out of lining (left side only).
If necessary, replace brake pad wear sensor.
Release guide screw (2).
If necessary, grip at hexagon head (3).
Tilt brake caliper upwards.
Installation:
Replace guide screws.
For tightening torque refer to 34 11 5AZ in 34 11 FRONT BRAKE .
Fig. 27: Guide Screws, Hexagon Head, Brake Pad Wear Sensor And Removal Directions
Remove brake pads (1) in direction of arrow from brake console.
IMPORTANT: Mark any worn brake pads.
In the event of one-sided brake pad wear, do not change brake pads round.
2007 BMW 335i
Observe minimum thickness of brake pads.
Clean brake pads.
Do not apply grease to brake pad backplate.
Fig. 28: Brake Pads And Removal Directions

 Position special tool 34 1 280 at three measuring points in area (1) and measure.
 Compare measurement result and lowest value with setpoint value.
New brake pads may only be installed if the brake disc thickness is greater than or equal to the minimum brake
disc thickness (MIN TH).
Fig. 29: Set Point Areas And Special Tool (34 1 280)
2007 BMW 335i
NOTE: The minimum thickness of the brake disc is designed so that it holds over the
service life of a further set of brake pads if it is greater than or equal to the
minimum brake disc thickness (MIN TH).
Press brake piston fully back with special tool 34 1 050 .
IMPORTANT: When pressing piston back, note brake fluid level in expansion tank.
Overflowing brake fluid will damage the paintwork.
Fig. 30: Special Tool (34 1 050) And Installation Directions

Check dust sleeve (1) for damage and replace if necessary.
Clean contact face (2) of brake piston and apply a thin coating of anti-squeak compound.
IMPORTANT: Dust sleeve must not come into contact with anti-squeak compound as this
may cause the dust sleeve to swell.
2007 BMW 335i
Fig. 31: Dust Sleeve And Brake Piston Contact Face

Clean contact face (1) of brake caliper and apply a thin coating of anti-squeak compound.
Fig. 32: Brake Caliper Contact Face

Clean hammerhead guides and apply a thin coating of anti-squeak compound.
IMPORTANT: Brake pad with indentation (1) is intended for accommodating the brake pad
wear sensor and must be fitted on the piston side.
Fig. 33: Brake Pad Indentation And Hammerhead Guides

Replacement:
Remove lining retaining springs (1).

2007 BMW 335i
Installation:
Clean contact face of brake carrier and apply a thin coating of anti-squeak compound.
Fig. 34: Retaining Springs

 Fully depress brake pedal several times so that brake pads contact brake
discs.
 When installing new brake pads at front and rear axles, brake fluid level
must be brought up to "MAX" marking.
 Read and comply with notes on braking in new brake discs / brake pads.
 When replacing linings, reset CBS display in accordance with factory
specification.
34 11 000 REMOVING AND INSTALLING OR REPLACING BRAKE PADS ON BOTH FRONT DISC
BRAKES (TEVES FLOATING CALIPER)
 Remove wheels
Lift out retaining spring (1).

2007 BMW 335i
Fig. 35: Retaining Spring And Removal Directions

Remove plastic plugs (1).
Fig. 36: Plastic Plugs

Unfasten guide screws (1) and lift out brake caliper towards rear of vehicle.
Installation:
Clean guide screws only; do not grease.
Check threads.
Replace all guide screws which are not in perfect condition.

2007 BMW 335i
IMPORTANT: Tie brake caliper back and do not allow to hang from brake hose.
Fig. 37: Guide Screws And Removal Direction

Remove outer brake pad.
Inner brake pad is located with its spring in the piston.
Clean brake pads.
Do not grease backs of brake pads sleeve.

2007 BMW 335i
Fig. 38: Outer Brake Pad And Removal Directions

NOTE: The minimum thickness of the brake disc is designed so that it holds over the
service life of a further set of brake pads if it is greater than or equal to the
minimum brake disc thickness (MIN TH).
Fig. 39: Set Points And Special Tool (34 1 280)

Turn piston fully back with special tool 34 1 050 .
IMPORTANT: When pressing down piston, note brake fluid level in expansion tank.

2007 BMW 335i


Clean contact faces (1...2) of brake pad hammer heads/brake caliper housing and coat with anti-squeak
compound.
2007 BMW 335i
Fig. 42: Brake Pad Hammer Contact Faces


Clean brake console at hammerhead guides and apply a thin coating of anti-squeak compound.
2007 BMW 335i
Fig. 44: Brake Console And Hammerhead Guides

discs.
specification.
34 11 000 REMOVING AND INSTALLING/RENEWING BRAKE PADS ON BOTH FRONT DISC

BRAKES (BREMBO)
IMPORTANT:  Brake pad wear sensor: after removal it must be replaced (brake pad wear
sensor loses its retention capability in the brake pad).
 Retaining spring: for vehicles older than 48 months it is recommended to
replace the retaining spring!
 Remove Wheels .
 Remove brake pad wear sensor.
Release bolts (1) and pull off brake caliper with brake anchor plate towards rear.
Installation:
2007 BMW 335i
Tightening torque: see 2AZ in 34 11 FRONT BRAKE .
Fig. 45: Release Bolts (1) And Pull Off Brake Caliper With Brake Anchor Plate Towards Rear
Turn piston back fully with special tool 34 1 050 .
Fig. 46: Turn Piston Back Fully With Special Tool 34 1 050
Pull brake pads (1) off guide pins (2) and remove.
IMPORTANT: Mark any worn brake pads. In the event of one-sided brake pad wear, do not
change brake pads round.

2007 BMW 335i
Installation: Clean brake pads, brake caliper and guide pins. Do not grease backs of brake pads sleeve. Brake
pads must be correctly seated on guide pins.
Fig. 47: Pull Brake Pads (1) Off Guide Pins (2) And Remove
 Compare measurement result and lowest value with setpoint value.
Fig. 48: Position Special Tool 34 1 280 At Three Measuring Points In Area (1) And Measure
IMPORTANT: New brake pads may only be fitted if the brake disc thickness is greater than
the minimum brake disc thickness (MIN TH).
IMPORTANT: Do not grease brake pads and guides with brake pad paste.
Clean contact surface (1) of brake pistons with brake cleaner.

2007 BMW 335i
Fig. 49: Clean Contact Surface (1) Of Brake Pistons With Brake Cleaner
Replace expanding spring (1).
Fig. 50: Replace Expanding Spring (1)

 When installing new brake pads at front and rear axles, brake fluid level
 Fully depress brake pedal several times so that brake pads contact brake
discs.
 Read and comply with notes on BRAKING IN NEW BRAKE DISCS / BRAKE
PADS.
 When replacing linings, reset CBS display in accordance with factory
specification.
34 11 000 REMOVING AND INSTALLING/REPLACING BRAKE PADS ON BOTH DISC BRAKES (6

2007 BMW 335i
PISTONS BREMBO)
sensor loses its retention capability in the brake pad).
IMPORTANT: So as not to damage the surface coating, if possible do not mechanically clean
the guide surfaces for the brake pads on the brake caliper mounting bracket.
Instead, clean with brake cleaner BMW part no. 83 19 2 154 780.
 Remove FRONT WHEELS .

 Remove brake pad wear sensor.
IMPORTANT: If the brake pads are old, they may be bonded to the brake pistons by an
adhesive layer.
After the brake pads are detached from the brake pistons, they must be
replaced with pads that are no longer bonded.
They must not be reused!
Brake pads that are not bonded can be reinstalled.
These brake pads must be greased with NEVER-SEEZ compound (see BMW
Electronic Parts Catalogue) before they are reinstalled.
Drive out retaining pin (1) in direction of arrow and remove retaining spring (2).
Fig. 51: Identifying Retaining Spring And Retaining Pin

2007 BMW 335i
Release screws (1) and remove brake caliper rearwards(2).
NOTE: Picture shows E7x M
Installation note:
Replace screws (1).
Fig. 52: Releasing Screws To Remove Brake Caliper Rearwards

Press back brake pads and piston with special tool 34 1 050 and remove brake pads!
NOTE: Picture shows E7xM
IMPORTANT: When forcing piston back:
 Pay attention to brake fluid level in expansion tank; brake fluid that spills
over will damage paintwork.
2007 BMW 335i
Fig. 53: Pressing Back Brake Pads And Piston With Special Tool (34 1 050)
Installation note:
Rear side of brake pads (1) must be thinly greased with NEVER-SEEZ compound (see Electronic Parts
Catalogue).
Fig. 54: Identifying Rear Side Of Brake Pad

the minimum brake disc thickness (MIN TH).
2007 BMW 335i
Fig. 55: Checking Brake Disc Thickness Using Special Tool (34 1 280)
NOTE: Picture shows E7xM
So as not to damage the surface coating, if possible do not mechanically clean pad guides (2). Clean with a
brake cleaner instead.
IMPORTANT: Do not grease brake pad guides (2).
Fig. 56: Identifying Brake Pad Guides

Observe installation sequence:
1. Insert brake pads in calliper

2. Install brake calliper on wheel carrier
2007 BMW 335i
Drive out 3rd retaining pin at bottom of brake calliper side (1) up to limit position.
Fig. 57: Locating 3rd Retaining Pin At Bottom Of Brake Calliper Side
Insert 4th retaining spring in brake calliper (see graphic) and press in far enough to drive in top retaining pin.
Graphic shows: retaining spring and retaining pin in installation position
Fig. 58: Inserting 4th Retaining Spring In Brake Calliper

NOTE: After completing repair work:
discs.
 Read and comply with notes on BRAKING IN NEW BRAKE DISCS / BRAKE
PADS.
2007 BMW 335i
34 11 020 REMOVING AND INSTALLING OR REPLACING FRONT LEFT OR RIGHT BRAKE

CALIPER (TRW)
 Remove wheels
 Read and comply with General Information.
After completing work: Bleed braking system
Press clutch pedal down to floor and secure with pedal support.
NOTE: The pedal support may only be released when the brake lines are reconnected.
This prevents brake fluid from emerging from the expansion tank and air from
entering the system when the brake lines are opened.
Fig. 59: Clutch Pedal And Pedal Support

If necessary, pull brake hose out of holder (1).
IMPORTANT: Grip brake hose at square head (3) to prevent connecting piece from turning in
retaining bracket.
Disconnect brake hose from brake line (2).
Installation:
For tightening torque refer to 34 32 1AZ in 34 32 BRAKE LINES .
Detach brake hose from brake caliper (4).
Installation:
2007 BMW 335i
Fig. 60: Holder, Brake Line, Square Head And Brake Caliper
IMPORTANT: Never twist brake hose when installing it and avoid all contact with parts
attached rigidly to the body.
NOTE: First tighten brake hose on brake caliper.
Move wheels into straight-ahead position.
Insert brake hose in bracket and screw onto brake pipe.
Pull brake pad wear sensor (1) towards rear out of lining (left side only).
Unscrew guide bolts (3).
Remove brake caliper by pulling upwards.
Installation:

2007 BMW 335i
Fig. 61: Brake Pad Wear Sensor, Hexagon Head And Guide Bolts
34 11 020 REMOVING AND INSTALLING OR REPLACING FRONT LEFT OR RIGHT BRAKE

CALIPER (TEVES)
 Remove wheels
2007 BMW 335i

retaining bracket.
Installation:
Installation:
2007 BMW 335i
Installation:
Check threads.
Fig. 64: Brake Pad Wear Sensor, Guide Bolts And Removal Direction
34 11 220 REMOVING AND INSTALLING/REPLACING BOTH FRONT BRAKE DISCS
 Remove WHEELS
 Remove and clean BRAKE PADS
2007 BMW 335i
NOTE: After completing work, read and comply with notes on BRAKING IN NEW
BRAKE DISCS / BRAKE PADS.
 Position special tool 34 1 280 GAUGE at three measuring points in area (1) and measure.
 Compare measurement result and lowest value with SETPOINT VALUE .
Installation:
New brake pads may only be fitted if the brake disc thickness is greater than the MINIMUM BRAKE DISC
THICKNESS (MIN TH).
If the brake discs are replaced, you must also fit new brake pads.
Brake discs may only be replaced in pairs (on each axle).
Fig. 65: Checking Minimum Brake Disc Thickness Using Special Tool (34 1 280)
Release screws (1) and remove brake anchor plate (2).
Installation:

2007 BMW 335i
Fig. 66: Identifying Screws Of Brake Anchor Plate

IMPORTANT: To release brake disc: Do not under any circumstances strike friction ring with
a hammer or similar!
If necessary, carefully tap on base of brake disc chamber with a rubber mallet.
Clean contact surface of brake disc at wheel hub thoroughly and remove traces
of corrosion.
Unevenness on contact surface may result in distortion of brake disc!
IMPORTANT: Brake discs must not be mixed up (directional ventilation).
Release screws (1) and remove brake disc.
Installation:
Brake disc must be correctly seated on guide pins (2).
Replace screw.

2007 BMW 335i
Fig. 67: Identifying Guide Pins And Brake Disc Screws

34 11 220 REMOVING AND INSTALLING/REPLACING BOTH FRONT BRAKE DISCS (BREMBO)
 Remove wheels.
 Remove and clean brake pads.
After completing work, read and comply with notes on BRAKING IN NEW BRAKE DISCS / BRAKE
PADS.
 Compare measurement result and lowest value with setpoint value. See BRAKES - TECHNICAL
DATA - SEDAN/WAGON .
If the brake discs are replaced, you must also fit new brake pads. Brake discs may only be replaced in pairs (on
each axle).
2007 BMW 335i
Fig. 68: Identifying Measuring Points

the minimum brake disc thickness (MIN TH). See 34 11 FRONT BRAKE E90 .
of corrosion.
Unevenness on contact surface may result in distortion of brake disc.
Release screw (1) and remove brake disc (2). Installation: Replace screw. Tightening torque 34 11 1AZ. See
FRONT BRAKES .
Fig. 69: Identifying Brake Disc With Mounting Screw

2007 BMW 335i
34 11 250 REMOVING AND INSTALLING / REPLACING A BRAKE CARRIER / BRAKE GUARD

PLATE AT FRONT
 Remove front brake disks
Release screws (1) and remove brake guard plate (2).
Installation:
Fig. 70: Brake Guard Plate And Screws

34 11 519 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT FRONT BRAKE

CALIPER
 Remove WHEELS .
 Read and comply with GENERAL INFORMATION.
 If necessary, replace BRAKE PAD SENSOR.
After completing work: BLEED BRAKING SYSTEM
2007 BMW 335i
Fig. 71: Identifying Brake Tensioner

retaining bracket.
Fig. 72: Identifying Brake Caliper, Brake Lines And Brake Hose Square Head
Installation:
Tightening torque: see 1AZ in 34 32 BRAKE LINES .

2007 BMW 335i
Installation:

Installation:
Check threads.
Fig. 73: Identifying Guide Bolts

34 11 520 REMOVING AND INSTALLING/REPLACING FRONT LEFT OR RIGHT BRAKE

CALIPER (BREMBO)
2007 BMW 335i
 Remove Wheels .
 Remove front brake pad sensor.
After completing work: Bleed braking system.
Fig. 74: Locating Pedal Support


2007 BMW 335i
Fig. 75: Pull Brake Hose Out Of Holder (1)

retaining bracket.
Disconnect brake hose from brake line (2). Installation: Tightening torque 34 32 1AZ, see 34 32 BRAKE
LINES .
Detach brake hose from brake caliper (4). Installation: Tightening torque 34 32 2AZ, see 34 32 BRAKE
LINES .
NOTE: First tighten brake hose on brake caliper. Move wheels into straight-ahead
position. Insert brake hose in bracket and screw onto brake pipe.
Release bolts (1) and pull off brake caliper with brake anchor plate towards rear. Installation: Tightening torque
34 11 2AZ, see 34 11 FRONT BRAKE .
2007 BMW 335i
Fig. 76: Release Bolts (1) And Pull Off Brake Caliper With Brake Anchor Plate Towards Rear
Pull brake pads (1) off guide pins (2) and remove.
Fig. 77: Pull Brake Pads (1) Off Guide Pins

IMPORTANT: Mark any worn brake pads. In the event of one-sided brake pad wear, do not
change brake pads round. Observe minimum thickness of brake pads. See 34
11 FRONT BRAKE E90 .
Installation: Clean brake pads, brake caliper and guide pins. Do not grease backs of brake pads sleeve. Brake
pads must be correctly seated on guide pins.
IMPORTANT: Do not grease brake pads and guides with anti-squeak paste.
Clean contact surface (1) of brake pistons.

2007 BMW 335i
Fig. 78: Clean Contact Surface (1) Of Brake Pistons

34 11 552 OVERHAULING LEFT OR RIGHT FRONT BRAKE CALIPER (TRW) (BRAKE CALIPER
REMOVED)
WARNING: In the following work step, large forces occur at the brake caliper piston
(up to more than 2800 N).
Danger of injury!
NOTE: Use repair kit.
Carefully force piston out through connection bore with compressed air.
To protect piston, place a protective plate (e.g. hard wood or hard felt) in caliper recess.
Do not grip piston with fingers - risk of trapping!
Fig. 79: Caliper Recess Protective Plate

2007 BMW 335i
Press off dust sleeve (1).
Fig. 80: Dust Sleeve

Carefully remove seal (1) with special tool Sealing lip wedge 00 9 316 in set 00 9 310 ASSEMBLY WEDGES
(SET IN PLASTIC CASE) .
Clean cylinder bores and parts with alcohol and dry with compressed air.
Thoroughly inspect cylinder bore, piston and flange surfaces.
Machining of cylinders and pistons is not permitted.
Install new seal.
Installation:
Apply a light coat of Ate brake cylinder paste to cylinder bore, piston and seal, refer to BMW Service
Operating Fluids .
2007 BMW 335i
Fig. 81: Seal And Special Tool (00 9 316)

Fit dust sleeve (1) in groove (2) of brake caliper housing and press into the annular groove.
Installation:
The area between the dust sleeve and the brake caliper housing must be kept dry. It must not come into contact
with Ate brake cylinder paste or brake fluid so as to ensure that the dust sleeve is perfectly seated.
Fig. 82: Dust Sleeve And Brake Caliper Housing Groove

Lightly press brake piston against dust sleeve (1).
Inflate dust sleeve with compressed air (max. 2 bar) via the connection hole. Dust sleeve snaps over brake
piston.
Installation:
2007 BMW 335i
Coat dust sleeve and brake piston with brake fluid to facilitate installation of dust sleeve.
Press piston into cylinder bore until dust sleeve (1) snaps into annular groove (2) of brake piston.
IMPORTANT: Do not twist brake piston.
Fig. 83: Dust Sleeve And Brake Piston Annular Groove

34 11 552 OVERHAULING LEFT OR RIGHT FRONT BRAKE CALIPER (BRAKE CALIPER

REMOVED)
Danger of injury!
NOTE: Use repair kit.
Check guide sleeves (5), fitting repair-kit guide sleeve if necessary.

2007 BMW 335i
Fig. 84: Guide Sleeves

Carefully force piston out through connection bore with compressed air.
To protect piston, place a protective plate (e.g. hard wood or hard felt) in caliper recess.
Fig. 85: Caliper Recess Protective Plate


2007 BMW 335i
Fig. 86: Dust Sleeve

Carefully remove seal (1) with special tool Sealing lip wedge 00 9 316 in set 00 9 310 ASSEMBLY WEDGES
(SET IN PLASTIC CASE) .
Clean cylinder bores and parts with alcohol and dry with compressed air.
Thoroughly inspect cylinder bore, piston and flange surfaces.
Machining of cylinders and pistons is not permitted.
Install new seal.
Installation:
Apply a light coat of Ate brake cylinder paste to cylinder bore, piston and seal,
Refer to BMW Service Operating Fluids .

2007 BMW 335i
Fig. 87: Seal And Special Tool (00 9 316)

Fit dust sleeve (1) in annular groove of piston (2).
Press piston into cylinder bore.
Evenly press dust sleeve (1) onto brake caliper housing as far as it will go.
Installation:
Fig. 88: Dust Sleeve And Piston

34 11 552 OVERHAULING LEFT OR RIGHT FRONT BRAKE CALIPER (BREMBO) (BRAKE

CALIPER REMOVED)
Danger of injury!
IMPORTANT: To protect the pistons, place a protective plate (1) (e.g. hard wood or hard felt)
in caliper recess. Do not grip piston with fingers - risk of trapping!
2007 BMW 335i
Fig. 89: Place A Protective Plate In Caliper Recess

Carefully force piston out through brake hose connection bore with compressed air.
Installation: Do not jam piston when pressing in.
Fig. 90: Press Off Dust Sleeve (1)

IMPORTANT: Machining of cylinders and pistons is not permitted.
Installation: Dust sleeve must be correctly seated in groove (1) of piston and groove (2) of brake caliper.
2007 BMW 335i
Fig. 91: Dust Sleeve Must Be Correctly Seated In Groove (1) Of Piston And Groove (2) Of Brake Caliper
34 11 667 PRECISION-TURNING BOTH FRONT BRAKE DISCS ON BOTH SIDES
IMPORTANT: Always precision-turn both sides of both brake discs on one axle.
Observe Max. machining dimension per friction ring side Minimum brake disc
thickness (MIN TH)
Brake discs of M models (Compound brake discs) must not be machined!
Only one brake pad set may be used up on brake discs which have been lathe-
turned to minimum thickness (MIN TH).
Stationary brake disc lathe:
In the case of stationary brake disc lathes, the brake disc must be removed.
Please refer to the lathe manufacturer's instruction manual for the exact procedure.
IMPORTANT: Only BMW-approved brake disc lathes may be used!

2007 BMW 335i
Fig. 92: Stationary Brake Disc Lathe

Mobile brake disc lathe:
In the case of mobile brake disc lathes, only the brake caliper has must be removed.
The brake discs remain on the car.
Fig. 93: Mobile Brake Disc Lathe

After fine-grinding the brake discs, measure the thickness difference inside the braking surfaces at 8 points
with an external micrometer.
2007 BMW 335i
Fig. 94: Measuring Thickness Of Brake Disc

REAR BRAKE
34 21... OVERVIEW OF REAR BRAKE
2007 BMW 335i
Fig. 95: Overview Of Rear Brake

34 00... CHECKING BRAKE DISCS
See CHECKING BRAKE DISCS.

AT REAR
 Remove expander lock

 Remove wheel hub
Release screws (1).
Installation:
2007 BMW 335i
For tightening torque refer to 34 21 3AZ in 34 21 REAR BRAKE .
Release screws (2) and remove brake carrier (3).
Installation:
Fig. 96: Brake Carrier And Screws


AT REAR
 Remove expander lock

 Remove wheel hub
Release screws (1).
Installation:
Release screws (2) and remove brake carrier (3).
Installation:

2007 BMW 335i
Fig. 97: Identifying Mounting Screws And Brake Carrier

34 21 173 REPLACING REAR LEFT (OR RIGHT) BRAKE CARRIER
 Remove expander lock.

 Remove wheel hub. See 33 41 153 REPLACING WHEEL BEARING (75 MM) ON REAR AXLE
SHAFT ON LEFT or 33 41 153 REPLACING WHEEL BEARING (85 MM) ON REAR AXLE
SHAFT ON LEFT .
Release screws (1). Installation: Tightening torque, see 34 21 3AZ in 34 21 REAR BRAKE .
Release screws (2) and remove brake carrier (3). Installation: Tightening torque, see 34 21 3AZ in 34 21 REAR
BRAKE . Release screws (1). Installation: Tightening torque, see 34 21 3AZ in 34 21 REAR BRAKE .
Fig. 98: Removing Brake Carrier

2007 BMW 335i
34 21 200 REMOVING AND INSTALLING OR REPLACING BRAKE PADS ON BOTH REAR DISC
BRAKES (TEVES FLOATING CALIPER)
 Remove wheels
Fig. 99: Retaining Spring And Removal Directions

Remove cover plug (1).
Fig. 100: Cover Plug

2007 BMW 335i
Remove brake caliper (2) by pulling forward.
Installation:
Check threads.
Fig. 101: Brake Caliper And Bolts

Clean brake pads.

2007 BMW 335i
Fig. 102: Outer Brake Pad And Removal Directions

Turn piston fully back with special tool 34 1 050 .

2007 BMW 335i


Clean contact faces (1...2) of brake pad hammer heads/brake caliper housing and coat with anti-squeak
compound.
2007 BMW 335i
Fig. 106: Brake Pad Hammer Contact Faces


Clean brake caliper mounting bracket at hammer head guides and apply a thin coating of anti-squeak
compound.
2007 BMW 335i
Fig. 108: Hammerhead Guides Brake Console

discs.
specification.
34 21 200 REMOVING AND INSTALLING OR REPLACING BRAKE PADS ON BOTH REAR DISC
BRAKES (TRW FLOATING CALIPER)
 Remove Wheels
 Remove Rear Brake Pad Wear Sensor
Release guide screw (1).
If necessary, grip at hexagon head.
Tilt brake caliper upwards.
Installation:

2007 BMW 335i
Fig. 109: Identifying Rear Brake Pad Guide Screws

Remove brake pads (1) in direction of arrow from brake console.
Observe Minimum Thickness Of Brake Pads.
Clean brake pads.
Do not apply grease to brake pad backplate.
Fig. 110: Identifying Brake Pads And Removal Direction

2007 BMW 335i
 Compare measurement result and lowest value with Setpoint Value.
New brake pads may only be installed if the brake disc thickness is greater than or equal to the Minimum
Brake Disc Thickness (MIN TH).
Fig. 111: Identifying Special Tool (34 1 280) And Brake Disc Measuring Points
Press brake piston fully back with special tool 34 1 050 .
IMPORTANT: When pressing piston back, note brake fluid level in expansion tank.

2007 BMW 335i
Fig. 113: Identifying Brake Caliper Dust Sleeve And Face

Fig. 114: Identifying Brake Caliper Contact Face

Clean hammerhead guides and apply a thin coating of anti-squeak compound.
IMPORTANT: Brake pad with indentation (1) is intended for accommodating the brake pad
wear sensor and must be fitted on the piston side.
2007 BMW 335i
Fig. 115: Identifying Brake Pad With Indentation

discs.
 Read and comply with Notes On BRAKING IN NEW BRAKE DISCS /
BRAKE PADS.
specification.
Replacement:
Remove lining retaining springs (1).
Installation:
Clean contact face of brake carrier and apply a thin coating of anti-squeak compound.
2007 BMW 335i
Fig. 116: Identifying Brake Pad Retaining Springs

34 21 200 REMOVING AND INSTALLING/REPLACING BRAKE PADS ON BOTH REAR DISC

BRAKES (BREMBO)
sensor loses its retention capability in the break pad).
 Retaining spring: for vehicles older than 48 months it is recommended to
replace the retaining spring!
So as not to damage the surface coating, if possible do not mechanically

clean the guide surfaces for the brake pads on the brake caliper mounting
bracket. Instead, clean with brake cleaner BMW part no. 83 19 2 154 780.
 Remove WHEELS
 Remove BRAKE PAD WEAR SENSOR
Drive out retaining pins (1).
Remove expanding spring (2).
Pull out brake pads (3) with special tool 34 1 000 (puller).

2007 BMW 335i
Fig. 117: Identifying Retaining Pins, Expanding Spring And Brake Pads
Clean brake pads.
Turn piston back fully with special tool 34 1 050 .
Fig. 118: Turning Piston Back Using Special Tool

2007 BMW 335i
 Position special tool 34 1 280 (gauge) at three measuring points in area (1) and measure.
 Compare measurement result and lowest value with SETPOINT VALUE .
Fig. 119: Positioning Special Tool (34 1 280) At Three Measuring Points
the MINIMUM BRAKE DISC THICKNESS (MIN TH).
IMPORTANT: Do not grease brake pads and guides with brake pad paste.
Clean brake caliper.
Check dust boot (1) for damage and replace if necessary.
Clean contact surface (2) of brake piston.

2007 BMW 335i
Fig. 120: Identifying Dust Boot And Contact Surface

 Fully depress brake pedal several times so that brake pads contact brake discs.
 When installing new brake pads at front and rear axles, brake fluid level must be brought up to "MAX"
marking.
 Read and comply with notes on BREAKING IN NEW BRAKE DISCS/BRAKE PADS.
 When replacing pads, reset CBS display in accordance with factory specification.
34 21 320 REMOVING AND INSTALLING OR REPLACING BOTH REAR BRAKE DISCS
 Remove wheels
 Remove and clean brake pads
After completing work:
 Adjusting handbrake
 Read and comply with notes on braking in new brake discs / brake pads.
2007 BMW 335i
disc thickness (MIN TH) .
If the brake discs are replaced, you must also fit new brake pads.
Always replace brake discs in pairs.

Release screws (1). Remove and suspend brake caliper from vehicle.
Installation:
Fig. 122: Brake Caliper And Screws

2007 BMW 335i
of corrosion.
Unevenness on contact surface may result in distortion of brake disc!
Release screws (1) and remove brake disc.
Installation:
Replace screws.
Fig. 123: Identifying Screws And Brake Disc

34 21 745 REMOVING AND INSTALLING OR REPLACING REAR LEFT OR RIGHT BRAKE

CALIPER (TRW)
 Remove wheels
 Read and comply with General Information
2007 BMW 335i

IMPORTANT: Grip brake hose at square head (2) so that connecting piece cannot rotate in
retaining bracket.
Installation:
Installation:

2007 BMW 335i
Fig. 125: Square Head, Brake Line And Brake Caliper

Pull brake pad wear sensor towards rear out of lining (right side only).
Remove brake caliper by pulling forward.
Installation:
Fig. 126: Guide Bolts And Hexagon Head

34 21 745 REMOVING AND INSTALLING OR REPLACING REAR LEFT OR RIGHT BRAKE

CALIPER (TEVES)
2007 BMW 335i
 Remove wheels

retaining bracket.
Installation:
Installation:

2007 BMW 335i

Fig. 129: Retaining Spring And Removal Direction

Remove cover plug (1).
Pull brake pad wear sensor out of brake pad (right side only).
2007 BMW 335i
Fig. 130: Cover Plug

Installation:
Check threads.
Fig. 131: Brake Caliper And Guide Bolts

2007 BMW 335i
Clean brake pads.
Fig. 132: Outer Brake Pad And Removal Direction

34 21 745 REMOVING AND INSTALLING/REPLACING REAR LEFT OR RIGHT BRAKE

CALIPER (BREMBO)
 Remove WHEEL
 Read and comply with GENERAL INFORMATION.
After completing work: BLEED BRAKE SYSTEM.
2007 BMW 335i
This prevents brake fluid from emerging from the expansion tank and air from entering the system when the
brake lines are opened.
Fig. 133: Identifying Brake Pedal Support

retaining bracket.
Installation:
Installation:

2007 BMW 335i
Fig. 134: Identifying Brake Hose Head, Brake Line And Brake Caliper
Release screws (1).
Installation:
Tightening torque: see 2AZ in 34 21 REAR BRAKE .
Fig. 135: Locating Brake Caliper Screws

Replacement:
Remove BRAKE PADS
34 21 812 OVERHAULING LEFT OR RIGHT REAR BRAKE CALIPER (BRAKE CALIPER

REMOVED)
(up to more than 2800 N). Risk of injury!
2007 BMW 335i
Check guide sleeves (5), fitting repair-kit guide sleeve if necessary.
Fig. 136: Check Guide Sleeves (5), Fitting Repair-Kit Guide Sleeve If Necessary
Carefully force piston out through connection bore with compressed air. To protect piston, place a protective
plate (e.g. hard wood or hard felt) in caliper recess. Do not grip piston with fingers - risk of trapping!
Fig. 137: Carefully Force Piston Out Through Connection Bore

Press off dust sleeve.
Carefully remove sealing ring (1) special tool Sealing lip wedge 00 9 316 in set 00 9 310 ASSEMBLY
WEDGES (SET IN PLASTIC CASE) . Clean cylinder bores and parts with alcohol and dry with compressed
air. Thoroughly inspect cylinder bore, piston and flange surfaces. Machining of cylinders and pistons is not
permitted. Install new seal.
2007 BMW 335i
Fig. 138: Carefully Remove Sealing Ring (1) Special Tool 00 9 316
Installation: Apply a light coat of Ate brake cylinder paste to cylinder bore, piston and seal.
Fit dust sleeve (1) in annular groove of piston (2). Press piston into cylinder bore.
Evenly press dust sleeve (1) onto brake caliper housing as far as it will go.
Fig. 139: Fit Dust Sleeve (1) In Annular Groove Of Piston

Installation: The area between the dust sleeve and the brake caliper housing must be kept dry. It must not come
into contact with Ate brake cylinder paste or brake fluid so as to ensure that the dust sleeve is perfectly seated.
34 21 812 OVERHAULING LEFT OR RIGHT REAR BRAKE CALIPER (BREMBO) (BRAKE

CALIPER REMOVED)
2007 BMW 335i
Risk of injury!
IMPORTANT: Do not under any circumstances press out brake piston entirely.
To protect the pistons, place a protective plate (1) (e.g. hard wood or hard felt) in caliper recess.
a = min. 35 mm
Fig. 140: Identifying Protective Plate

Carefully force piston out through brake hose connection bore with compressed air.
Installation:
Do not jam piston when pressing in.

2007 BMW 335i
Fig. 141: Identifying Dust Sleeve

IMPORTANT: Machining of cylinders and pistons is not permitted.
Installation:
Dust sleeve must be correctly seated in groove (1) of piston and groove (2) of brake caliper.
Fig. 142: Identifying Dust Sleeve And Brake Caliper Housing

34 21 947 PRECISION-TURNING BOTH REAR BRAKE DISCS ON BOTH SIDES
IMPORTANT: Always precision-turn both sides of both brake discs on one axle.
2007 BMW 335i
Observe Max. machining dimension per friction ring side
Minimum brake disc thickness (MIN TH)
Brake discs of M models (Compound brake discs) must not be machined!
Only one brake pad set may be used up on brake discs which have been lathe-
turned to minimum thickness (MIN TH).
Stationary brake disc lathe:
In the case of stationary brake disc lathes, the brake disc must be removed.
Fig. 143: Stationary Brake Disc Lathe

Mobile brake disc lathe:
In the case of mobile brake disc lathes, only the brake caliper has must be removed.
The brake discs remain on the car.

2007 BMW 335i
Fig. 144: Mobile Brake Disc Lathe

After fine-grinding the brake discs, measure the thickness difference inside the braking surfaces at 8 points
with an external micrometer.
Fig. 145: Measuring Thickness Of Brake Disc

MASTER BRAKE CYLINDER

34 31... OVERVIEW OF BRAKE MASTER CYLINDER / BRAKE BOOSTER
2007 BMW 335i
Fig. 146: Overview Of Brake Master Cylinder / Brake Booster

34 31 181 REMOVING AND INSTALLING / REPLACING EXPANSION TANK FOR HYDRAULIC

BRAKE ACTUATION

 Remove lower section of microfilter housing
NOTE: Suck the brake fluid out of the expansion tank. Use a suction bottle used
exclusively for drawing off brake fluid.
Do not reuse drawn out brake fluid.

2007 BMW 335i
 Bleed braking system
Pull off supply hose (1) of clutch hydraulic system if necessary.
Unlock quick-release fastener (3) and disconnect vacuum line.
Feed brake line out of rubber grommet and remove cover (4).
Fig. 147: Plug Connection, Cover, Supply Hose And Quick-Release Fastener
Unclip locking pin (1) from retaining lugs (2) and pull out locking pin.
Pull expansion tank in direction of arrow vertically out of brake master cylinder.
Fig. 148: Locking Pin, Retaining Lugs And Removal Direction

2007 BMW 335i
IMPORTANT: Check rubber plug in brake master cylinder for damage and replace if
necessary.
Push the expansion tank vertically onto the master brake cylinder.
Fig. 149: Expansion Tank, Brake Master Cylinder And Installation Direction
34 31 505 REMOVING AND INSTALLING / REPLACING MASTER BRAKE CYLINDER FOR DSC
 Remove expansion tank.

 Remove footwell trim.
 Bleeding brake system with DSC
IMPORTANT: The brake booster must be slackened so that the brake master cylinder can be
removed and installed without tilting!
Remove locking clip (1) and disengage and pull out locking pin.
Slacken nuts (2).
Installation:
For tightening torque refer to 35 11 1AZ in 35 11 PEDAL ASSEMBLY CONSOLE .

2007 BMW 335i
Fig. 150: Locking Clip And Slacken Nuts

IMPORTANT: Do not bend brake lines.
Unfasten brake lines (1).
Installation:
Close off brake lines and brake master cylinder with plugs 32 1 270 .
If necessary, detach line (3) from hydraulic unit and press downwards slightly.
Installation:
Release nuts (2) and feed brake master cylinder out of brake booster.
2007 BMW 335i
Fig. 151: Brake Lines, Nuts, Line And Removal Direction

Installation:
For tightening torque refer to 34 31 1AZ in 34 31 BRAKE MASTER CYLINDER .
Installation:
Fig. 152: Sealing Ring

Installation:
When inserting the brake master cylinder (2) into the brake booster (1), make sure the pressure rod of the brake
booster and that of the brake master cylinder meet each other on one level.
2007 BMW 335i
Fig. 153: Brake Master Cylinder And Brake Booster

BRAKE LINES
34 32... OVERVIEW OF BRAKE LINES
2007 BMW 335i
Fig. 154: Overview Of Brake Lines

34 32 861 REPLACING ALL BRAKE PIPES
NOTE: The brake lines are only supplied in the straight version and correct length with
connecting nipple.
Read and comply with General Information.
After completing work, bleed brake system.
Observe safety instructions on raising the vehicle.
New brake lines are bent into shape with bending tool 34 5 100 .
Removed brake pipes can be used as templates for bending.

2007 BMW 335i
IMPORTANT:  Protective coating of brake line must not be damaged during bending.
 Do not kink or bend back brake lines.
 Watch distances to rigid and movable vehicle parts. Brake lines may not
make contact or rub.
 Tighten down brake line couplings with torque wrench.
Installation:

34 32 881 REPLACING FRONT LEFT OR RIGHT BRAKE HOSES
NOTE:  Read and comply with General information.
Press clutch pedal down to floor and secure with pedal support
2007 BMW 335i

Cars up to model year approx. 07/05:
Pull brake hose out of holder (1).
Detach brake hose from brake line (2).
retaining bracket.
Installation:
2007 BMW 335i
Installation:
Cars from model year approx. 07/05:
Pull brake hose out of both holders (1).
retaining bracket.
Installation:
Installation:
Fig. 158: Brake Line, Brake Caliper Square Head And Holders
IMPORTANT: First tighten brake hose on brake caliper.
Never twist brake hose when installing it and avoid all contact with parts
2007 BMW 335i
34 32 881 REPLACING FRONT LEFT OR RIGHT BRAKE HOSE (AWD)
NOTE: Read and comply with GENERAL INFORMATION.
After completing work: BLEED BRAKING SYSTEM.
This prevents brake fluid from emerging from the expansion tank and air from entering the system when the
brake lines are opened.
Fig. 159: Identifying Brake Pedal Support

Detach retainer (1) from bracket on spring strut in upward direction.
Installation:
Retainer (1) must be felt and heard to snap into place.
Ensure correct seating in guide.

2007 BMW 335i
Fig. 160: Detaching Retainer From Bracket On Spring Strut

Pull brake hose out of holder (1).
retaining bracket.
Installation:
Detach brake hose from brake calliper (4).
Installation:

2007 BMW 335i
Fig. 161: Identifying Brake Hose Connections

IMPORTANT: First tighten brake hose on brake calliper.
34 32 951 REPLACING REAR LEFT OR RIGHT BRAKE HOSE (BETWEEN REAR AXLE
CARRIER AND BODY)

 Remove rear left wheel
NOTE: After completing work:Bleed braking system

IMPORTANT: Grip brake hose at square drive to prevent connecting piece from turning in
2007 BMW 335i
retaining bracket.
Never twist brake hose (3) when installing it and avoid all contact with parts
Detach brake hose from brake line (2) and remove brake hose (3).
Installation:
Fig. 163: Brake Hose And Brake Lines

Installation:
Tighten brake line using torque wrench (Hazet 6282-1CT with reversible ratchet head) and special tool 34 3
170 .
2007 BMW 335i

34 32 980 REPLACING REAR LEFT OR RIGHT BRAKE HOSE (BETWEEN BRAKE CALIPER AND
PIPE)
NOTE:  Read and comply with General Information.
After completing work:Bleed braking system

retaining bracket.
Installation:

2007 BMW 335i
Installation:

Installation:
First tighten brake hose on brake caliper.
BRAKE BOOSTER
34 33 051 REMOVING AND INSTALLING OR REPLACING NON-RETURN VALVE FOR BRAKE
BOOSTER

 Remove hydraulic unit
IMPORTANT:  If a rubber vacuum hose is fitted, it can be replaced individually.

 If a plastic vacuum line is fitted, it can only be replaced as a single unit
together with the non-return valve.
NOTE: Before beginning work, fully press the brake pedal several times to reduce the
vacuum pressure in the brake booster. This makes it easier to remove the non-
return valve.
2007 BMW 335i
Remove non-return valve (1) from brake booster.
Unlock quick-connect coupling (2) and detach vacuum line.
Disconnect plug connection (3) and remove differential pressure sensor.
Feed out vacuum line.
Installation:
Check sealing ring in brake booster and replace if necessary.
Fig. 167: Non-Return Valve, Quick-Connect Coupling, Plug Connection And Removal Directions
34 33 071 REPLACING VACUUM HOSE FOR BRAKE BOOSTER (N52 ON BRAKE BOOSTER)

IMPORTANT: Before beginning work, fully press the brake pedal several times to reduce the
vacuum pressure in the brake booster.
Unlock quick-release fastener (1) and pull out vacuum line (2).
2007 BMW 335i
Fig. 168: Quick-Release Fastener, Vacuum Line And Removal Direction

Installation:
Replace hose clip.
Pull off vacuum hose (2).
Unclip vacuum line (4) from fixture (3) and feed out.
Fig. 169: Vacuum Hose, Hose Clip Vacuum Line And Fixture
34 33 071 REPLACING VACUUM HOSE FOR BRAKE BOOSTER (N52 ON VACUUM PUMP)

2007 BMW 335i

 Removing intake air manifold
IMPORTANT: Before starting work, press the brake pedal to the floor several times to reduce
the vacuum pressure in the brake booster.
This makes it easier to detach the vacuum hose.
Unclip vacuum line from fixture (2).
Release hose clamp (3) and disconnect vacuum line.
Installation:
Replace hose clamps.
Fig. 170: Vacuum Hose Clip, Fixture And Hose Clamp

34 33 505 REMOVING AND INSTALLING OR REPLACING BRAKE BOOSTER

 Remove brake master cylinder
 Remove left footwell trim
Detach locking clip (1) from brake pedal, disengage and pull out locking pin.
2007 BMW 335i
Unscrew nuts (2).
Installation:
For tightening torque refer to 35 11 1AZ in 35 11 PEDAL ASSEMBLY CONSOLE .
Fig. 171: Locking Clip And Slacken Nuts

Carefully pull brake booster (1) out of bulkhead and tilt out.
If necessary, disengage brake line from holder on bulkhead and press slightly to one side.
IMPORTANT: Do not use any force when removing and installing the brake unit; the brake
unit can be damaged under certain circumstances.
Brake lines must not be bent.
The non-return valve must be modified when the brake booster is replaced.
2007 BMW 335i
Fig. 172: Brake Booster And Removal Direction

ELECTRICAL COMPONENTS/WEAR INDICATOR

34 35 001 REPLACING A BRAKE PAD SENSOR (FRONT)
If a brake pad sensor that has already been ground has to be replaced even
though the minimum brake pad thickness has not yet been reached, you must
observe the following: The new sliding contact must be filed down with a file to
the same length as the ground sliding contact.
 Remove wheel
Open plug housing (1).
Unclip lead of brake lining sensor (2) from plug housing (1).
Disconnect associated plug connection of lead from brake lining sensor (2).
Feed lead from brake lining sensor (2) out of fixtures.

2007 BMW 335i
Fig. 173: Identifying Brake Plug Housing And Sensor (Version 1)

Fig. 174: Identifying Brake Plug Housing And Sensor (Version 2)

Press clip (1) together and detach brake lining sensor (2) in direction of arrow from brake caliper (3).
Installation:
Make sure clip (1) and brake lining sensor (2) are correctly seated in brake caliper (3).
2007 BMW 335i
Fig. 175: Clip, Brake Lining Sensor, Brake Caliper And Removal Directions
34 35 003 REPLACING A BRAKE PAD SENSOR (REAR)
If a brake pad sensor that has already been ground has to be replaced even
though the minimum brake pad thickness has not yet been reached, you must
observe the following: The new sliding contact must be filed down with a file to
the same length as the ground sliding contact.
 Remove wheel
Slacken nut (1).
Pull wheel arch trim (2) gently to one side.
Disengage cable from holders (3).

2007 BMW 335i
Fig. 176: Wheel Arch Trim, Holder, Nut And Removal Direction
Installation:
Ensure proper locking of the plug connector and proper seating of the cable in the brackets.

Detach brake pad wear sensor (2) in direction of arrow from brake caliper (3).
Installation:
Make sure holders (1) and brake pad wear sensor (2) are correctly seated in brake caliper.
2007 BMW 335i
Fig. 178: Cable Holders And Brake Pad Sensor

PARKING BRAKE
34 10 014 ADJUSTING PARKING BRAKE
Perform inspection in the following manner:
When 1st ratchet is engaged, no braking force should be exerted.
The difference in wheel circumferential forces between the left and right wheels may deviate by max. 30 %
from the greater value (measured on brake analyzer).
In event of larger deviations of wheel circumferential force: carry out readjustment.
The handbrake must be readjusted whenever the actuation stroke is greater than 10 teeth.
NOTE: The handbrake can only be adjusted correctly when the parking brake Bowden
cables and all moving handbrake parts are free to move and fully operational.
Basic handbrake adjustment is necessary:
 When replacing parking brake shoes.

 When replacing brake disks.
 In event of excessive actuation stroke (10 teeth).
 When replacing handbrake cables.
1. Setting instruction for brake shoes (basic setting)
Unclip gaiter for handbrake lever.

2007 BMW 335i
Release handbrake lever.
Lock adjuster unit (ASZE).
Using special tool 32 1 030 , press stop (1) of adjusting spring back to such an extent that retaining hook
(2) engages in stop (1).
Installation:
Unlock adjuster unit (ASZE).
Lever out restraining hook (2) with a suitable screwdriver.
Restraining hook (2) must detach from stop (1) of adjusting spring.
Fig. 179: Restraining Hook, Stop, Special Tool (32 1 030) And Removal Directions
Completely unscrew one wheel stud on each rear wheel.
Installation:
For tightening torque refer to 36 10 1AZ in 36 10 WHEELS .
Turn wheel until adjustment screw is visible in tapped hole.

2007 BMW 335i
Fig. 180: Wheel Stud

Turn adjusting screw with a screwdriver until the wheel is no longer able to turn.
Then unfasten the adjusting screw 8 notches.
Fig. 181: Brake Adjustment Screw

2007 BMW 335i
IMPORTANT: Follow instructions for Brake testing on test stand.
2. Setting instruction for parking brake Bowden cables
The handbrake lever must be applied 5 times to approx. 400N actuating force.
1. On brake analyzer
0th tooth (handbrake released):

Vehicles with manual transmission: Shift lever in neutral position.
Vehicles with automatic transmission: Selector lever in "N" position.
 Without locking differential < or =150 N.
 With locking differential < or = 200 N (possibly odd display).
5th tooth: The brake force display must have reached > or = 400 N.
Apply handbrake until a wheel circumferential force (brake force display) of min. 1000 N is reached.
Max. permitted brake force differential right/left < or = 35 % (referred to greater brake value).
3. Braking in the duo-servo parking brake

2007 BMW 335i
The following braking-in procedures are applicable in case of insufficient braking effect or after replacing
brake disks and/or brake shoes.
1. On brake analyzer
Apply handbrake lever until wheel circumferential force on first wheel is 800 N.
Lock lever in next lower tooth.
Release handbrake lever after approx. 2 minutes.
2. When driving on road
(If possible inside the company grounds or on an unused road) At approx. 40 km/h, apply
handbrake lever until braking action
can be felt.
Pull up handbrake lever into next notch and drive on for approx. 400 m.
A basic requirement is that handbrake is adjusted uniformly.
NOTE: If necessary, repeat braking-in procedure.
Allow brake to cool down sufficiently.
34 41... OVERVIEW OF PARKING BRAKE

2007 BMW 335i
Fig. 183: Overview Of Parking Brake

34 41... REMOVING AND INSTALLING OR REPLACING GAITER FOR PARKING BRAKE LEVER
Unclip gaiter with special tool Trim panel wedge 00 9 317 in set 00 9 310 ASSEMBLY WEDGES (SET IN
PLASTIC CASE) .
2007 BMW 335i
Fig. 184: Special Tool (00 9 317) And Gaiter Removal Direction
Pull gaiter (1) over handbrake lever.
Cut cable ties (2) and remove gaiter.
Installation:
Eye of cable tie must face downward
Fig. 185: Handbrake Gaiter And Cable Ties

34 41 000 REMOVING AND INSTALLING / REPLACING PARKING BRAKE LEVER

 Remove airbag control unit
2007 BMW 335i
 Adjust handbrake
Using special tool 32 1 030 , press stop (1) of adjusting spring back to such an extent that retaining hook (2)
engages in stop (1).
Installation:
Release screws (1).
For tightening torque refer to 34 41 5AZ in 34 41 PARKING BRAKE .
Remove bracket for center console (2).

2007 BMW 335i
Fig. 187: Centre Console Bracket And Screw

Disconnect cable (1) from handbrake check switch.
Unclip cable bracket (2) at point (3).
Remove cable bracket and place forward.
Fig. 188: Cable, Cable Bracket And Point

Press retainer (1) in balance arm (2) forward in direction of arrow.
Detach handbrake Bowden cables (3) from balance arm (2).

2007 BMW 335i
Fig. 189: Retainer, Balance Arm, Bowden Cables And Removal Directions
Release nuts (1) and remove handbrake lever (2).
Installation:
Handbrake lever and adjustment unit (ASZE) are only exchanged completely as a single unit.
Fig. 190: Handbrake Lever And Nuts

34 41 071 REPLACING HANDLE FOR PARKING BRAKE LEVER

2007 BMW 335i
 Remove gaiter for handbrake lever
Pull off handle for handbrake lever (1) in direction of arrow.
Installation:
Handbrake lever grip (1) must snap audibly into place.
Fig. 191: Handbrake Lever And Removal Direction

34 41 120 REMOVING AND INSTALLING OR REPLACING BOTH PARKING BRAKE BOWDEN

CABLES
2007 BMW 335i
Fig. 192: Stop, Retaining Hook And Special Tool (32 1 030)
Installation:

2007 BMW 335i
Fig. 194: Holder And Screw

NOTE: To release the parking brake Bowden cable from the expander lock, it is
necessary to remove the brake disk on the following vehicles:
 E90 330i 330d

 All E91
Release one wheel stud.
Bring wheel into position (tapped hole turned down approx. 20° from horizontal).
F = direction of travel
Installation:
Reinstall wheel stud only after handbrake has been adjusted.
For tightening torque refer to 36 10 1AZ in 36 10 WHEELS .

2007 BMW 335i
Fig. 195: Tapped Hole Angle

Nipple (1) and expander lock (2) are visible through tapped hole.
Push in core of handbrake cable in direction of expander lock as far as it will go and grip firmly.
Press nipple (1) downwards through tapped hole with a screwdriver.
Pull handbrake cables out of wheel carrier.
Fig. 196: Nipple, Expander Lock And Removal Direction

Installation:
Insert handbrake cable into brake carrier/brake guard plate.
Sleeve must be inserted up to stop.
Nipple of handbrake cable must audibly snap into place in expander lock.
Disconnect handbrake cables from holders (1).
Pull handbrake cables towards rear out of guide tube.

2007 BMW 335i
Fig. 197: Handbrake Cable Holders And Removal Directions

34 41 140 REMOVING AND INSTALLING OR REPLACING GUIDE TUBE FOR PARKING BRAKE
CABLES

 Remove propeller shaft
Installation:
2007 BMW 335i
Pull handbrake cables out of guide tube.
Release screws (1).
Release screws (2) and feed out guide tube (3) towards bottom.
Installation:
Replace seal.
2007 BMW 335i
Fig. 200: Screws, Guide Tube And Removal Directions

34 41 220 REMOVING AND INSTALLING/REPLACING ALL PARKING BRAKE SHOES
 Remove rear brake disk
2007 BMW 335i
Disconnect return spring (1) with brake spring pliers.
Installation:
Check and if necessary replace return spring (1).
Pay attention to installation position of adjustment screw (2).
Apply a thin coat of grease to bush and screw threads.
Fig. 202: Return Spring And Adjustment Screw

Disconnect return spring (1) with brake spring pliers.
Installation:
2007 BMW 335i
Check and if necessary replace return spring (1).
Fig. 203: Return Spring

Turn clamping pins (1) with special tool 34 4 000 through 90° and disconnect.
Remove brake shoes (2).
Fig. 204: Clamping Pins, Brake Shoes And Special Tool (34 4 000)
34 41 250 REMOVING AND INSTALLING/REPLACING EXPANDER LOCK FOR PARKING

BRAKE SHOES
 Remove handbrake shoes

2007 BMW 335i
Pull expander lock (1) forwards, disconnect handbrake Bowden cable (2) and remove expander lock.
Fig. 206: Expander Lock, Bowden Cable And Removal Direction

MECHANICAL-HYDRAULIC COMPONENTS
34 51 527 REMOVING AND INSTALLING OR REPLACING DSC HYDRAULIC UNIT

2007 BMW 335i

 Extract brake fluid
NOTE: Extract brake fluid out of expansion tank. Use a suction bottle used exclusively
for drawing off brake fluid.
Do not reuse drawn out brake fluid.
IMPORTANT: Do not mix up brake lines.
If necessary, mark before removal.
Close off connection bores with plugs.
Press cover (2) slightly to one side and disconnect plug connection (1).
Unfasten brake lines (3).
Installation:
Fig. 207: Brake Lines, Plug Connection And Cover

Unscrew nuts (1).

2007 BMW 335i
Installation:
For tightening torque refer to 34 51 6AZ in 34 51 SLIP CONTROL SYSTEM (DSC) .
Fig. 208: Nuts

IMPORTANT: If necessary, release brake lines from holder on bulkhead.
Brake lines must not be bent!
Tilt out hydraulic unit (1) in direction of side panel.
Fig. 209: Hydraulic Unit And Removal Directions

When replacing hydraulic unit:
Release screws (1) and convert holder (2).

2007 BMW 335i
Installation:
Modify DSC control unit.
Fig. 210: Identifying Convert Holder Screw

When replacing control unit:
 Carry out programming/coding

 Adjustment of steering angle sensor
 Mix-up check of brake lines
 Function check, hydraulic unit
ELECTRONIC COMPONENTS
34 52... OVERVIEW OF ELECTRONIC COMPONENTS
2007 BMW 335i
Fig. 211: Overview Of Electronic Components

34 52 516 REMOVING AND INSTALLING/REPLACING DSC CONTROL UNIT
Protection).
IMPORTANT: Risk of damage to the contacts when removing and installing the hydraulic
unit.
Release screws (1) and carefully detach control unit (2) towards front.
2007 BMW 335i
Fig. 212: Control Unit And Screws

IMPORTANT: Replace all seals in area (1).
Fig. 213: Seal Area

Installation:
Keep sealing faces clean.
Replace screws.
Observe tightening sequence (1-4).

2007 BMW 335i
Fig. 214: Screw Tightening Sequence

Replacement:

 Steering angle sensor adjustment
or
Carry out adjustment for active front steering
 Mix-up check of brake lines

 Function check, hydraulic unit
34 52 525 REPLACING ONE FRONT PULSE SENSOR
Open connector housing (1), pull plug connector (2) out of bracket and disconnect.
Pull cable with rubber grommet out of holders (3).
Installation:
Ensure proper locking of plug connector and proper seating of rubber grommets.
2007 BMW 335i
Fig. 215: Plug Housing, Plug Connection And Holders

Release hexagon socket head cap screw (1) and pull wheel speed sensor (2) out of bore.
Installation:
Clean bore hole for pulse generator and grease with Staburags NBU 12/K lubricating grease (refer to BMW
Service Operating Fluids ).
Fig. 216: Hexagon Socket Head Cap Screw And Wheel Speed Sensor
34 52 535 REPLACING A REAR PULSE SENSOR
 Remove wheels.
2007 BMW 335i
Unscrew nut (1).
Pull wheel arch trim (2) gently to one side.
Fig. 217: Wheel Arch Trim, Nut And Holders

Installation:
Ensure proper locking of the plug connector and proper seating of the cable in the brackets.

2007 BMW 335i
Unfasten socket head cap screw (2).
Withdraw wheel speed sensor (3) from bore hole.
Installation:
Clean bore hole for pulse generator and grease with Staburags NBU 12/K lubricating grease (refer to BMW
Service Operating Fluids ).
Fig. 219: Cable Holders, Cap Screw And Wheel Speed Sensor
34 52 550 REMOVING AND INSTALLING / REPLACING DSC SENSOR
Protection).
 Remove left front seat

 Remove front left entrance cover strip
Lift carpet (1) and fold back to side.
Remove underlay (2).
Disconnect plug connection.
Installation:
2007 BMW 335i
Ensure proper locking of plug connector.
Slacken screws (3)
Release screws (4) and remove bracket with yaw sensor.
Installation:
Fig. 220: Screws, Carpet And Underlay

When replacing DSC sensor:
Release screws (1) and modify DSC sensor (2).
Installation:

2007 BMW 335i
Fig. 221: DSC Sensor And Screws

34 52 700 REPLACING DSC HYDRAULIC CONTROL UNIT (VALVE BLOCK)
protection).
 Remove hydraulic unit.

 Immediately close off all hydraulic connections with protective caps!
 Clean outside of control unit.
IMPORTANT:  The hydraulic unit must not be more than 7 years old.
 May only be replaced once. Check repair history!
 No longer install hydraulic unit if subjected to mechanical stress
(dropped, impact).
 Then use lint-free cloths and cleaning agent free of mineral oil.
 Do not touch any contact surfaces on the connector, pressure sensor and
control unit with the hand or objects.
TROUBLESHOOTING
34 90... TROUBLESHOOTING BRAKE SYSTEM
TROUBLESHOOTING BRAKE SYSTEM CHART

Fault Cause Remedy
a. Correct tire inflation

pressure
2007 BMW 335i
b. Change or replace tires

a. Tyre inflation pressure not in c. Replace brake pads,
keeping with regulations Check for causes
b. Unevenly worn tire treads d. Replace brake pads,
c. Oil on pads/liners Check for causes
d. Wrong type of pads/liners e. Replace guide bolts
Brakes pull to one side f. Check wheel alignment
e. Guide bolts dirty or damaged
f. Axle geometry not correct g. Remove and install, repair
or replace floating calipers
g. Corrosion in floating calipers
h. Check shock absorber,
h. No shock absorber action replacing if necessary
i. Pad of one caliper worn i. Replace brake pads,
check floating caliper
a. Replace master brake
a. Compensating port in brake master cylinder
cylinder blocked b. Replace master brake
b. Swollen rubber parts due to use of cylinder
Brakes excessively hot wrong brake fluid c. Clean expansion tank
while driving c. Bleeder hole on expansion tank d. Remove and install, repair
blocked or replace floating calipers
d. Corroded floating calipers e. Check handbrake and
e. Handbrake lever not released fully handbrake Bowden
cables, repair if necessary
Poor braking effect in
spite of great force on
Brake pads oil-splattered or burnt; wrong
pedal Replace brake pads
type of brake pads
Travel at brake pedal
normal
Brake booster malfunctions - engine
pedal Check brake booster
vacuum
Travel at brake pedal too
short
One brake circuit failed due to leaks or
pedal Leakage test of brake system
damage
Travel at brake pedal too
long
a. Air in brake system
Brake pedal can be b. Not enough brake fluid in expansion a. Bleed brakes
pressed down softly and tank b. Top up or change brake
springily fluid Bleed brakes
c. Overheated brake fluid - vapor lock
due to excessive water content in c. Change brake fluid, Bleed
2007 BMW 335i
brake fluid or excessive brake loads brakes

a. Primary cup seal in brake master a. Replace master brake
Brake is bled and cylinder damaged cylinder
readjusted, but brake pedal b. Leaking separating cup seals on b. Replace master brake
can be pressed down too floating piston of brake master cylinder
far cylinder c. Leakage test of brake
c. Leak in brake system system
a. Replace brake pads
b. Remove and install,
a. Wrong type of pads/liners repair or replace floating
b. Dirty fist caliper recesses, damaged calipers
caps c. Remove and install,
Uneven pad wear
c. Corrosion in floating calipers repair or replace floating
d. Swollen rubber ring for piston calipers
control d. Remove and install,
repair or replace floating
calipers
a. Replace wheel bearings
a. Wheel-bearing play excessive b. Check floating caliper
installation
b. Brake disk not aligned with fist
caliper c. Remove and install,
c. Corrosion in floating calipers
Brake pads worn at angle calipers
d. Angular brake-disk wear
d. Grind or replace brake
e. Minimum lining thickness undershot disks
f. Spring force insufficient e. Replace brake pads
g. Guide bolts damaged f. Replace spring
g. Replace guide bolts
a. Remove and install,
a. Dirty fist caliper recesses, damaged
calipers
Seized brake pads, pad caps
does not move off brake b. Remove and install,
b. Corrosion in floating calipers
disk repair or replace floating
c. Compensating port in brake master calipers
cylinder blocked
c. Replace master brake
cylinder
a. Replace brake pads

a. Wrong type of pads/liners b. Remove and install/clean
b. Dirty floating caliper recesses floating calipers
c. Spring force insufficient c. Replace spring
d. Brake disk not aligned with fist d. Check floating caliper
2007 BMW 335i
caliper installation
e. Brake-disk runout e. Replace brake discs
f. Excessive thickness deviation within f. Measure brake disk
braking surface thickness Grind or replace
g. Liner wear excessive or one-sided disks
Brakes squeal or rattle
h. Rust edges on brake disks g. Replace brake shoes
i. Pad loose h. Grind or replace brake
disks
j. Wheel-bearing play excessive
i. Replace brake pads
j. Replace wheel bearings
a. Wheel-bearing play excessive b. Check floating caliper
b. Brake disk not aligned with fist installation
caliper c. Replace brake discs
c. Brake-disk runout d. Measure brake disk
Brake-pedal dead travel
excessive d. Excessive thickness deviation within thickness Grind or replace
braking surface disks
e. Brake system leaking e. Leakage test of brake
f. Air in brake system system
g. Wrong type of pads/liners f. Bleed brakes
g. Replace brake pads
a. Remove and install,
a. Dirty fist caliper recesses, damaged
caliper
caps
Jammed piston in brake b. Check floating caliper
caliper b. Brake disk not aligned with fist
installation
caliper
c. Remove and install,
c. Pistons corroded in floating calipers
caliper
a. Wheel-bearing play excessive
b. Check floating caliper
b. Brake disk not aligned with fist
installation
Pulsating effect on brake caliper
pedal c. Replace brake discs
c. Brake-disk runout
d. Measure brake disk
d. Excessive thickness deviation within
thickness Grind or replace
braking surface
disks
a. Replace brake shoes,
determine cause
Handbrake effect
insufficient a. Brake shoes oil-splattered b. Adjust handbrake
b. Excessive dead travel between brake c. Remove and install
shoes and brake drums handbrake and expander
2007 BMW 335i
c. Corroded transmitting elements locks
Check Bowden cables,

replacing if necessary
2007 BMW 335i
TRANSMISSION Clutch - Repair Instructions
TRANSMISSION
Clutch - Repair Instructions
MAINTENANCE AND INSPECTION

21 00 006 BLEEDING CLUTCH HYDRAULIC SYSTEM
 21 5 030
 Remove transmission underbody protection if necessary.

 Remove microfilter housing is necessary.
IMPORTANT: From 08.06 a plastic Clutch Slave Cylinder is installed in the E8X, E9X.
Important notes on installation are described in this work step.
Unfasten nuts and remove clutch slave cylinder (pressure line remains connected).
Fig. 1: Clutch Slave Cylinder And Nuts

Fit special tool 21 5 030 on clutch slave cylinder (1).
Press piston rod (2) with aid of spindle completely into clutch slave cylinder.
2007 BMW 335i
Fig. 2: Special Tool (21 5 030), Piston Rod And Clutch Slave Cylinder
Connect bleeder unit to brake fluid expansion tank.
Connect bleeder hose to bleed valve (1).
Hold clutch slave cylinder in illustrated position (refer to Fig. 3) with special tool 21 5 030.
Open bleeder valve (1).
If bubble-free brake fluid emerges, retract piston rod (2) of clutch slave cylinder with aid of spindle a little and
press in again.
If no air bubbles escape, close bleeder valve (1), otherwise repeat procedure.
IMPORTANT: Do not under any circumstances remove special tool 21 5 030 from clutch slave
cylinder when brake system is pressurized.
Piston with push rod can jump out of clutch slave cylinder.
Switch off bleeder unit or remove from brake fluid expansion tank.
2007 BMW 335i
Fig. 3: Special Tool (21 5 030), Bleeder Valve, Clutch Slave Cylinder Piston Rod And Removal Directions
Slowly retract piston rod (2) of clutch slave cylinder (1) with special tool 21 5 030.
Remove special tool 21 5 030 from clutch slave cylinder (1).
Fig. 4: Special Tool (21 5 030), Piston Rod And Clutch Slave Cylinder
Fit clutch slave cylinder to transmission.
Installation:
For tightening torque refer to 21 52 5AZ in 21 52 CLUTCH OPERATION (HYDRAULIC) .

2007 BMW 335i
Fig. 5: Clutch Slave Cylinder And Nuts

Correct brake fluid level in expansion tank.
21 00 006 BLEEDING CLUTCH HYDRAULICS (PLASTIC SLAVE CYLINDER)
 Remove underbody protection from transmission.
Connect bleeder unit to brake fluid expansion tank.
Connect bleeder hose to bleed valve (1).
Open bleed valve (1) and flush until clear brake fluid emerges without air bubbles.
Close bleed valve.

2007 BMW 335i
Fig. 6: Brake Fluid Bleeder Valve

Switch off bleeder unit or remove from brake fluid expansion tank.
Correct brake fluid level in expansion tank.
CLUTCH WITH DRIVING DISC

21 21 500 REMOVING AND INSTALLING OR REPLACING CLUTCH (SAC 228)
 11 2 170
 21 2 141
 21 2 142
 21 2 170
 21 2 180
 21 2 201
 21 2 230
 21 2 250
 Remove TRANSMISSION .
Installation:
Screws must be replaced.

2007 BMW 335i
Identification SAC clutch dia. 240 mm (Self Adjusting Clutch):
 3 openings each with a pressure piece (1) of adjustment ring and a pressure spring (2)
NOTE: Fig. 7 shows new position of pressure pieces.
Fig. 7: Pressure Piece And Pressure Spring

Block flywheel with special tool 11 9 260.
Fig. 8: Special Tool (11 9 260) And Flywheel

Unfasten bolts and remove SAC clutch from flywheel.
IMPORTANT: Do not use a special tool to detach SAC clutch from flywheel.
2007 BMW 335i
Fig. 9: SAC Clutch Mounting Bolts

Remove clutch plate (1) from flywheel.
Clean flywheel, check for wear and damage.
Replace (N52K) or (N51) damaged flywheel.
Check grooved ball bearing in crankshaft for ease of movement and tightness and if necessary replace grooved
ball bearing.
Fig. 10: Flywheel Clutch Plate

IMPORTANT: Always replace clutch plates fouled e.g. by oil, cleaning agent.
Check clutch plate for damage and friction rust in hub profile and replace if necessary.
Check clutch disk for wear:

2007 BMW 335i
Measure lining protrusion at lining rivets at closing head (A) in each case.
NOTE: Rivet connection
A. Closing head
B. Swage head
Replace clutch plate if lining protrusion at closing head (A) is less than 1 mm.
Push clutch disk onto the cleaned transmission input shaft and check for easy movability.
Fig. 11: Clutch Plate Rivet Closing And Swag Heads

IMPORTANT: Do not clean SAC clutch with high-pressure cleaner or washing machine as
this may impair function of adjustment unit.
Clean friction surface only.
Check SAC clutch for wear and damage and replace if necessary.
Reinstalling removed SAC clutch and clutch plate:
Installation:
N52
Set SAC clutch (1) down on a clean surface.

2007 BMW 335i
Install special tool 21 2 180 in SAC clutch (1).
Fig. 12: Special Tool (21 2 180) And SAC Clutch

NOTE: Locking hooks (1) of special tool 21 2 180 must engage in openings in SAC
clutch.
Fig. 13: Locking Hooks, Special Tool (21 2 180) And Removal Direction
Press special tool 21 2 180 together at handles (1) as far as it will go and grip firmly.
At same time tighten down knurled screws (2).
Adjustment ring of SAC clutch is now secured in its original position (wear position).
IMPORTANT: Do not reset adjustment ring to new position.

2007 BMW 335i
Fig. 14: Special Tool (21 2 180), Handles And Knurled Screws
NOTE: Insert special tool 21 2 170 only in area of bores for dowel pins.
Fig. 15: Dowel Pins Bore Areas

Fit special tool 21 2 170 and tighten down at knurled screw (1).
2007 BMW 335i
Fig. 16: Special Tool (21 2 170) And Tightening Screw

Screw in spindle (1) until diaphragm spring (2) is tensioned up to stop.
Fig. 17: Spindle, Diaphragm Spring And Tightening Direction

IMPORTANT: Handle clutch disk carefully, do not touch surfaces of friction pads.
Install clutch plate in correct position.
Note designation for "engine side" / "transmission side".
Installation:
N52

2007 BMW 335i
Centre clutch plate (1) with special tool.
SPECIAL TOOL SPECIFICATIONS

Special tool Transmission
21 2 141 S6S 420G; S6S 560G; S5D 390Z
21 2 142 S5D 200G; S5D 250G; S5D 260Z; S5D 310Z
21 2 201 GS6-37BZ
21 2 230 GS6-53DZ
21 2 250 GS6-17BG
Fig. 18: Special Tools And Clutch Plate

Fit SAC clutch (1) on flywheel.
Pay attention to dowel pins (2).
SAC clutch (1) must be secured by way of dowel pins (2).
Insert screws and tighten down.
For tightening torque refer to 21 21 1AZ in 21 21 CLUTCH DISC AND DRIVE PLATE .
2007 BMW 335i
Fig. 19: SAC Clutch, Dowel Pins And Special Tool

Release spindle (1) until tension is completely removed from diaphragm spring (2).
Fig. 20: Diaphragm Spring, Spindle And Release Direction

Release knurled screw (1) and remove special tool 21 2 170 from SAC clutch.
2007 BMW 335i
Fig. 21: Special Tool (21 2 170, Knurled Screw And Removal Direction
Release knurled screws (2) and remove special tool 21 2 180 from SAC clutch.
Fig. 22: Special Tool (21 2 180) And Knurled Screws

Withdraw special tool from clutch plate with aid of accompanying screw (1).
2007 BMW 335i
Fig. 23: Accompanying Screw And Special Tools

Installing removed SAC clutch with new clutch plate:
Installation:
N52
IMPORTANT: Before installing an SAC clutch which has been in service with a new clutch
plate: always reset adjustment ring in new position.
Set SAC clutch down on a clean surface.
Install special tool 21 2 180 in SAC clutch (1).

2007 BMW 335i
Fig. 24: Special Tool (21 2 180) And SAC Clutch

NOTE: Locking hooks (1) of special tool 21 2 180 must engage in openings in SAC
clutch.
Fig. 25: Locking Hooks, Special Tool (21 2 180) And Removal Direction
NOTE: Insert special tool 21 2 170 only in area of bores for dowel pins.
Fig. 26: Dowel Pins Bores

Fit special tool 21 2 170 and tighten down at knurled screw (1).
2007 BMW 335i
Fig. 27: Special Tool (21 2 170) And Knurled Screw

Screw in spindle (1) until adjustment ring of SAC clutch (2) can be turned with special tool 21 2 180 at handles
(3).
Fig. 28: Special Tool (21 2 180), SAC Clutch, Spindle, Handles And Installation Direction
Press special tool 21 2 180 together at handles (3) as far as it will go and grip firmly.
At same time tighten down knurled screws (2).
Adjustment ring of SAC clutch is now secured in new position.

2007 BMW 335i
Fig. 29: Special Tool (21 2 180), Handles And Knurled Screws
Screw in spindle (1) until diaphragm spring (2) is tensioned up to stop.
Fig. 30: Installation Direction, Spindle And Diaphragm Spring

IMPORTANT: Handle clutch plate with care, do not touch surfaces of friction linings.
Install clutch plate in correct position.
Pay attention to text "engine end" / "transmission side".
Installation:
N52

2007 BMW 335i

21 2 141 S6S 420G; S6S 560G; S5D 390Z
21 2 142 S5D 200G; S5D 250G; S5D 260Z; S5D 310Z
21 2 201 GS6-37BZ
21 2 230 GS6-53DZ
21 2 250 GS6-17BG
Fig. 31: Special Tools And Clutch Plate

Fit SAC clutch (1) on flywheel.
Pay attention to dowel pins (2).
SAC clutch (1) must be secured by way of dowel pins (2).
Insert screws and tighten down.
2007 BMW 335i
Fig. 32: SAC Clutch, Flywheel And Dowel Pins

Release spindle (1) until tension is completely removed from diaphragm spring (2).
Fig. 33: Spindle, Diaphragm Spring And Release Direction

Release knurled screw (1) and remove special tool 21 2 170 from SAC clutch.
2007 BMW 335i
Fig. 34: Special Tool (21 2 170), Knurled Screw And Release Direction
Release knurled screws (2) and remove special tool 21 2 180 from SAC clutch.
Fig. 35: Special Tool (21 2 180) And Knurled Screws

2007 BMW 335i
Fig. 36: Accompanying Screw And Special Tools

Installing new SAC clutch:
Installation:
N52
IMPORTANT: Handle clutch disk carefully, do not touch surfaces of friction pads.
Install clutch plate (1) in correct position.
Note designation for "engine side" / "transmission side".

21 2 141 S6S 420G; S6S 560G; S5D 390Z
21 2 142 S5D 200G; S5D 250G; S5D 260Z; S5D 310Z
21 2 201 GS6-37BZ
21 2 230 GS6-53DZ
21 2 250 GS6-17BG
2007 BMW 335i
Fig. 37: Clutch Plate And Special Tools

Push SAC clutch onto dowel pins (1) located in flywheel and screw down.
Fig. 38: Flywheel Screw And Dowel Pins

IMPORTANT: Locking piece (1) may only be removed with SAC screw-mounted clutch!
Carefully unscrew locking piece (1) clockwise or counterclockwise with a hexagon socket wrench 14 A/F (2).
NOTE: A slight snapping of the plate spring while unscrewing is possible.

2007 BMW 335i
Fig. 39: Locking Piece, Hexagon Socket Wrench 14 A/F And Removal Direction
Fig. 40: Special Tool, Accompanying Screw And Clutch Plate

CLUTCH RELEASE CONTROLLER WITH LEVER

21 51 500 REMOVING AND INSTALLING OR REPLACING CLUTCH RELEASE BEARING/LEVER
NOTE: (transmission removed)
New version (except M models)
Release bearing and release lever have been combined to form a single release module.
If possible, do not disassemble the release module. Otherwise, there is a risk of the release module being
2007 BMW 335i
incorrectly reassembled.
Installation:
Make sure that the correct cam (1) of the release bearing is on the sliding surface (2) of the release lever.
NOTE: Do not grease sliding surfaces (2).
Fig. 41: Identifying Release Bearing And Lever Surface

4-cylinder gasoline engines:
Image "1" in Fig. 42: Cam (1) of release bearing (A=12 mm ) is on sliding surface of release lever.
6-cylinder gasoline and diesel engines:
Image "2" in Fig. 42: Cam (1) of release bearing (A=7 mm ) is on sliding surface of release lever.
Fig. 42: Identifying Release Bearing And Lever Surface

2007 BMW 335i
Remove release module (1) from spring wire clip.
Remove release module.
NOTE: Illustration similar.
Fig. 43: Removing Release Module From Spring Wire Clip

Installation:
Check spring wire clip (5) and ball pin (6) for damage and replace if necessary.
Fig. 44: Identifying Spring Wire Clip And Ball Pin

Previous version
Detach release bearing (1).

2007 BMW 335i
Installation note:
Clean all sliding surfaces on clutch release bearing, check for damage and replace if necessary.
Do not grease clutch release bearing.
Sliding surfaces (2) of clutch release bearing must rest on sliding surfaces (3) of release lever.
Apply a thin coating of GREASE to sliding surfaces (2) of release bearing.
Fig. 45: Removing Release Bearing

IMPORTANT: Only on E60/E61M5 M5 and E63/E64 M6 (7-speed SMG transmission) - lightly

grease guide sleeve.
Previous clutch release bearing:
Clutch release bearing with moving thrust plate (1).
Swivel motion of thrust plate (1) possible.

2007 BMW 335i
Fig. 46: Moving Thrust Plate

Withdraw release lever (4) from spring wire clip (5) and remove.
Installation note:
Clean release lever.
NOTE: Similar to graphic.
Fig. 47: Removing Release Lever From Spring Wire Clip

Previous release lever
Installation note:
Apply a thin coating of GREASE to release lever at sliding surfaces (1 and 2) only.
2007 BMW 335i
Fig. 48: Identifying Grease Applying Area

Installation note:
Check spring wire clip (5) and ball pin (6) for damage and replace if necessary.
Apply a thin coating of GREASE to ball pin (6).
NOTE: The spring wire clip and ball pin must always be replaced on the S6S 420G
transmission.
Illustration similar.
Fig. 49: Identifying Spring Wire Clip And Ball Pin

Clean guide sleeve (7).
Installation:
Except for E60/61 M5 and E63/64 M6 (7-speed SMG transmission) - do not grease guide sleeve.
2007 BMW 335i
If guide sleeve is greased, the release lever can stick on the guide sleeve.
NOTE: Similar to graphic.
Fig. 50: Identifying Guide Sleeve

CLUTCH OPERATION HYDRAULIC

21 52 500 REMOVING AND INSTALLING/REPLACING CLUTCH MASTER CYLINDER
NOTE: After completing work, bleed Regular or Plastic Slave Cylinder clutch hydraulic
system.
 Remove Trim Panel for pedal assembly.

2007 BMW 335i

Draw off brake fluid up to supply hose of clutch hydraulic system (1). For this purpose, use only a vacuum pipe
that is exclusively used for removing brake fluid.
Detach supply hose (1) from expansion tank.
Fig. 52: Brake Fluid Supply Hose

Release screws (1) on cylinder (2).
For tightening torque refer to 21 52 4AZ in 21 52 CLUTCH OPERATION (HYDRAULIC)

2007 BMW 335i
Fig. 53: Screws And Cylinder

Disconnect return spring (1).
Detach locking clip (3) and pull clutch pedal with clutch master cylinder off bearing block.
Press pin ends (2) together and remove pin.
Installation:
Replace locking clip.
The locking clip must be seated with both legs in the pin groove.
Fig. 54: Return Spring, Pin And Locking Clip

Detach retainer (1) with a screwdriver (2).

2007 BMW 335i
NOTE: Do not foul carpet with brake fluid.
Detach hydraulic line from clutch master cylinder.
Fig. 55: Retainer And Screwdriver

Detach supply hose (1) from clutch master cylinder.
IMPORTANT: Do not pull supply hose completely into interior.
Fig. 56: Clutch Master Cylinder Supply Hose

Lever out shift element (1) from clutch master cylinder (2) with screwdriver.
Release plug connection (3) and disconnect plug (4) from shift element (1).
2007 BMW 335i
Fig. 57: Plug Connection, Clutch Master Cylinder, Shift Element, Plug And Removal Direction
Installation:
Shift element is secured against incorrect installation.
Shift element must snap audibly into place.
Fig. 58: Clutch Master Cylinder

21 52 510 REMOVING AND INSTALLING OR REPLACING CLUTCH SLAVE CYLINDER
 13 3 010
NOTE: After completing work bleed Regular or Plastic Slave Cylinder clutch hydraulic
system.
2007 BMW 335i
IMPORTANT: From 08.06 a plastic Clutch Slave Cylinder is installed in the E8X, E9X.
Important notes on installation are described in this work step.
Seal supply hose to clutch master cylinder with special tool 13 3 010.
NOTE: Illustration shows E46.

Remove transmission underbody protection if necessary.
Release union screw (1) on hydraulic line.
Release nut (2) and remove hydraulic line (3) with bracket.
Installation:
Version with throttle valve, for tightening torque refer to 21 52 12AZ in 21 52

CLUTCH OPERATION (HYDRAULIC) .
2007 BMW 335i
Fig. 60: Screw, Nut And Hydraulic Line

Release nut and remove clutch slave cylinder.
Installation:
Fig. 61: Clutch Slave Cylinder Retaining Nut

Installation:
Clean thrust member (1) and contact face on release lever (2).
Lightly grease thrust member (1) on contact face (3).
Grease, refer to BMW Service Operating Fluids .

2007 BMW 335i
Fig. 62: Thrust Member, Contact Face And Release Lever

IMPORTANT: Spacer between fuel line and pressure hose of clutch slave cylinder must be
correctly fitted.
Fig. 63: Fuel Line And Pressure Hose Spacer

21 52 510 REMOVING AND INSTALLING/REPLACING CLUTCH SLAVE CYLINDER (PLASTIC)
 13 3 010
NOTE: After completing work bleed Regular or Plastic Slave Cylinder clutch hydraulic
system.
Seal hydraulic line to clutch slave cylinder with special tool 13 3 010.
2007 BMW 335i
Fig. 64: Special Tool (13 3 010) And Hydraulic Line

Release nuts and remove clutch slave cylinder (1) with holder (2).
Installation:
Fig. 65: Clutch Slave Cylinder, Holder And Self-Locking Nuts

Unlock spring retainer (1).
Disconnect hydraulic line (2).

2007 BMW 335i
Fig. 66: Spring Retainer And Hydraulic Line

Press cylinder together by hand.
Connect hydraulic line with cylinder pressed.
Fig. 67: Hydraulic Line Compression Direction

Hold cylinder piston vertically downwards.
Press piston 5 times into cylinder.

2007 BMW 335i
Fig. 68: Pressing Piston Compression Direction

Press in piston until it engages.
Install clutch slave cylinder.
Bleed Clutch Hydraulics.
Installation:
Clean thrust member (1) and contact face on release lever.
Lightly grease thrust member (1) on contact face (2).
Grease, refer to BMW Service Operating Fluids .
Fig. 69: Thrust Member, Contact Face And Compression Direction

2007 BMW 335i
TROUBLESHOOTING
21 90... TROUBLESHOOTING THE CLUTCH
TROUBLESHOOTING CHART
Fault Cause Remedy
a. Clutch pressure too low.
b. Lining too heavily worn.
c. Lining oiled-Leaks:
 Engine
Crankshaft radial seal at front and rear

incl. end cover, oil sump, cylinder
head gasket, cylinder head, oil filler
cap, timing case cover, flywheel
mounting bolts
a. Replace clutch Refer to 21 21
500.
 Cooling system
b. Replace clutch plate 21 21
Hoses and connections, heating 500.
Clutch slipping valves, sealing plugs on engine block c. Carefully rectify leaks, clean
oil contamination and replace
 Steering unit clutch plate 21 21 500.
d. Replace clutch 21 21 500.
Steering gear, servo pump, hydraulic e. Install original-equipment
lines and connections BMW part.
 Transmission
Drive shaft radial seal, sealing plugs

of countershaft
 Release bearing
d. Clutch was overheated.
e. Clutch is not an original-equipment BMW
part.
a. Replace clutch plate 21 21

500.
b. Replace clutch plate 21 21
a. Lining not acc. to specification. 500.
b. Lining oiled: Causes: refer to "clutch c. Check release lever.
slipping, point c"
d. Replace clutch
c. Release unit presses on one side.
d. Clutch presses at an angle. 21 21 500.
2007 BMW 335i
e. Crankshaft does not align with transmission e. Check engine/transmission

input shaft. contact face, adapter sleeves
f. Engine and transmission suspension and cover plate for damage.
defective. f. Replace engine and
Clutch g. Clutch plate not an original-equipment transmission suspension.
stick/slip BMW part. g. Install original-equipment
h. Engine, speed characteristics not O.K. BMW part.
i. Engine management not OK (particularly on h. Eliminate causes according to
diesel engine). engine test.
i. Check engine control unit.
Clutch releases
poorly (Gear Refer to BMW Service Information

difficult to bulletin 23 01 96 (096).
engage)
a. Replace clutch plate 21 21
500.
b. Evenly sand flywheel with
a. Lining of clutch plate broken. sandpaper (120-180 grain) and
replace clutch plate.
b. Lining rusted onto flywheel.
Clutch does not c. Replace guide bearing in
c. Guide bearing for transmission input shaft in
separate (Gear crankshaft.
crankshaft defective.
cannot be d. Replace faulty parts and bleed
engaged) d. Leak in clutch hydraulic system.
clutch hydraulics Refer to 21
e. Tangential leaf springs of clutch bent down. 00 006.
f. Release unit binds on guide sleeve. e. Replace clutch 21 21 500.
f. Clean guide sleeve, remove
and install release unit Refer
to 21 51 500.
TROUBLESHOOTING CHART
Fault Cause Remedy
a. Imbalance of clutch and clutch plate
a. Replace clutch/clutch plate 21 21 500.
too great.
b. Replace clutch plate 21 21 500 or if
b. Torsional-vibration damper defective.
Clutch necessary replace dual-mass flywheel.
noise c. Release unit defective.
c. Replace release unit Refer to 21 51 500.
d. Guide bearing for transmission input
d. Replace guide bearing in crankshaft.
shaft in crankshaft defective.
e. Replace clutch 21 21 500.
e. Clutch rivet connection loose.
2007 BMW 335i
ACCESSORIES AND EQUIPMENT Convertible Top - Repair Instructions
Convertible Top - Repair Instructions
MOTOR OPERATED CONVERTIBLE TOP

54 34... REPAIR INSTRUCTIONS FOR HYDRAULIC SYSTEM OF CONVERTIBLE TOP AND
CONVERTIBLE TOP COMPARTMENT LID
Definitions of terms
Hydraulic system at zero pressure  Turn ignition lock to "0" Hydraulic system has no or only
or position. very low pressure
Untensioned state:
 E46c: Wait 15 seconds
E52: Wait 2 minutes
E85: Emergency operation

or wait 2 minutes
E64/F12: Wait 5 seconds
 E88/E93: Wait 10 minutes

Mechanical operation:  Soft top is opened or closed Observe Point 3
Emergency operation: by hand
 Always move soft top with
aid of a second person
Closed system:  All lines are connected Even "short circuiting" of lines is
possible
Function check:  Open and close soft top Refer to Operating Instructions
several times (min. 3 times)
 Check fluid level in
hydraulic unit; if necessary,
top up fluid
Short circuit (E46c only):  Unfastening of quick-release Hydraulic system cannot build up
couplings pressure
Soft top can be moved
 Connection of supply and
return lines
Function check:  Checking of soft top Soft top must be secured!
function if possible on Move 2-3 times
removed soft top
Soft top stowed:  Soft top fully open (folded When the soft top is installed, it is
together) in the closed soft top compartment
2007 BMW 335i
When working on hydraulic system, observe the following
 Once it has been removed, the soft top must be safely stowed or tensioned (e.g. with screw clamps to
workbench).
 When the hydraulic system is open (unscrewing of lines, topping up of fluid, etc.), always provide
sufficient cloths to catch leak-off fluid.
Also provide an adherent protective cover to cover/protect fittings.
 Hydraulic system must be at zero pressure.

 E46c only: The disconnected supply and return lines to the soft top can be connected to each other
(establish "short circuit"). The system is thereby closed again. The clutches are protected against damage.
The hydraulic system cannot build up a high pressure. The soft top can be moved.
 Disconnect or unscrew feed and return lines if possible at a later stage, when the soft top is stowed and
untensioned (check fluid, see also Point 3).
 Once the hydraulic system has been opened, first check the fluid level after completing the tasks before
carrying out a function test.
 After disconnecting the hydraulic lines from hydraulic components, do not move the soft top if at all
possible (fluid can escape from joints).
 Piston rods must not be damaged (e.g. scratches). Even paint mist and welding spots are harmful.
When working in the vicinity of hydraulic cylinders, cover the cylinders with suitable materials.
 If the hydraulic unit or the lines stay removed for an extended period of time, the bores on the hydraulic
unit and the hose connections must be sealed off (observe installation instructions).
Mechanical soft top operation
 E46c: only with ignition switched off.
If lines are disconnected, connect them to each other if at all possible.
 E52/E64/E85/E88/E93: Emergency operation

 In the event of repeated operation, the system fluid is pumped into the supply tank of the hydraulic unit. If
hydraulic components are now replaced, there will be too much fluid in the system. This may cause
damage to the system in event of operation. (Checking fluid level, see Points 4 and 5).
Check oil level
 E46c: only when soft top is stowed and soft top compartment lid is closed.
E52E85only with soft top closed
 Observe brief instructions.

 Fluid level must be within the markings (circle/cross).
2007 BMW 335i
 Fluid is supplied with the repair kits (e.g. banjo bolts/seals, hoses, cylinders) and is available separately
(refer to BMW Parts Department).
Topping up/extracting fluid
 E46c: only when soft top is stowed and soft top compartment lid is closed. E52E85only with soft top
closed
 E64/F12: The hydraulic fluid does not have to be changed because the system is filled with life-time
fluid. Only the approved hydraulic fluid may be used in the event of leaks.
 Observe brief instructions.
 Remove hydraulic unit without detaching lines.
 Fluid is supplied with the repair kits (e.g. banjo bolts/seals, hoses, cylinders) and is available separately
(refer to BMW Parts Department).
 Pour in fluid with bottle through filler opening.
 Hydraulic unit must be removed if overfilled. Allow fluid to escape through filler opening and collect.
Bleeding hydraulic system
 E64/F12: if there is a significant build-up of noise while the soft top is moving, the soft top must be
opened and closed several times. The hydraulic system is automatically bled in the fluid reservoir in the
process.
54 34... REPAIRING WIND DEFLECTOR FIXING
Overview of spare parts in wind deflector repair kit:
Wind deflector repair kit: Part number 54 34 7 358 170
1. Detent pin
2. Compression spring
3. Slide
2007 BMW 335i
Fig. 1: Identifying Components Of Wind Deflector Repair Kit

Slide detent pin (1) through the wind deflector opening (2).
Guide compression spring (3) into the detent pin (1).
Fig. 2: Identifying Compression Spring, Wind Deflector Opening, And Detent Pin
Press detent pin (1) completely into the guide on the wind deflector (2).
Fig. 3: Pressing Detent Pin Completely Into Guide On Wind Deflector

Press slide (1) as far as it will go into the opening of the detent pin (2).
2007 BMW 335i
Fig. 4: Pressing Slide As Far As It Will Go Into Opening Of Detent Pin

Press slide (1) down into the guide of the wind deflector (2).
Installation note:
Slide (1) must engage fully in the guide on the wind deflector (2).
Run a function check.
Fig. 5: Pressing Slide Down Into Guide Of Wind Deflector

54 34... TOPPING UP/EXTRACTING FLUID, CHECKING FLUID LEVEL
NOTE: No changing of the hydraulic fluid necessary.
 The hydraulic fluid does not have to be changed because the system is filled with life-time fluid.
 Only the approved hydraulic fluid may be used in the event of leaks.
2007 BMW 335i
 All hydraulic cylinders must be completely extended.
Checking fluid level:
Fluid level must be within the markings (arrow) when the unit is horizontal.
Fig. 6: Locating Fluid Level Mark

Topping up fluid:
Align hydraulic unit horizontally.
Open oil filler plug.
Pour in required amount of fluid from fluid bottle.
Installation:
Check fluid level in the meantime.
Pour in hydraulic fluid only up to marking on fluid reservoir.

2007 BMW 335i
Fig. 7: Locating Oil Filler Plug Mark

IMPORTANT: Protect components and work area with suitable materials (e.g. cloths).
Extracting fluid:
Open oil filler plug.
Tilt hydraulic unit and let fluid flow out or draw off with a suitable auxiliary apparatus.
Fig. 8: Locating Oil Filler Plug Mark

FOLDING ROOF
54 37... 0 GENERAL NOTES REGARDING REPAIR AND TROUBLESHOOTING ON THE
HARDTOP
The hardtop is a complex mechanical system. Proper function is achieved through precise adjustments of
all components at the works.
2007 BMW 335i
Not all components can be adjusted at the works.
To avoid secondary problems after repairs, only repairs and adjustments that are explicitly approved by
BMW may be performed.
Thorough troubleshooting must always be completed prior to beginning with hardtop repairs.
In addition to the diagnosis system and repair instructions, video sequences are available on DVD.
VHT E93 Analysis and repair instructions Part 1 (01 69 0 038 434).
VHT E93 Analysis and repair instructions Part 2 (01 69 0 038 662).
NOTE: Troubleshoot in the event of water penetration according to the specifications

on the DVD.
2007 BMW 335i
Fig. 9: Display Diagnosis System

41 00... PROCEDURE FOR FOLDING ROOF AFTER AN ACCIDENT
The folding roof may be under tension after the vehicle has incurred damage following an accident. Moving the
folding roof by hydraulic means may result in irreparable damage. For this reason, the folding roof may only be
moved manually until the damaged has been repaired.
IMPORTANT: It is not possible to check the correct operation of the folding roof on the
damaged vehicle.
Different procedures are required, depending on the degree of damage which the vehicle has incurred. The
repair instructions for emergency actuation describe only the complete sequences for manually opening and
2007 BMW 335i
closing the folding roof.
When removing the roof module and/or the rear end module, it is possible to move the folding roof manually
into the necessary intermediate positions in each case.
WARNING: Risk of injury due to the heavy weight of the folding roof!
Since the hydraulic system may have to be depressurized during manual
movement of the folding roof, there is an increased risk of injury by
trapping. Always secure the folding roof adequately against unintentional
movement.
After body repairs to the vehicle
All the folding roof components screwed/bolted to the body are precisely screwed/bolted to the vehicle at the
factory by means of gauges. This affects above all the base plates and mounting brackets of the roof and rear
end modules. To minimize extensive adjustment work after a body repair as much as possible, only remove
those components which are screwed/bolted to a damaged body part.
 Gauge the base plates only after a body repair to the cowl panel.
54 37... ADJUSTING REAR ROOF SHELL
 Convertible top compartment lid must be correctly adjusted. See 41 63 068 ADJUSTING
CONVERTIBLE TOP COMPARTMENT LID .
Open convertible top until screws are accessible.
IMPORTANT: Lock barrel screws with a flat wrench without fail.

Barrel screws on roof shell must not move out of position.
Slacken screws (1) on left and right (do not unscrew completely).
2007 BMW 335i
Fig. 10: Identifying Slacken Screws

Slacken screw (1) on left and right (do not unscrew completely).
Fig. 11: Identifying Slacken Screw

Close convertible top.
Carefully press roof shell at convertible top compartment lid.
Press roof shell until:
 a uniform gap dimension and

 lower edge parallel with convertible top cover
are obtained over the entire length.
Hold roof shell in position while screwing down.
NOTE: Carry out this operation on the left and right sides in succession.
2007 BMW 335i
Fig. 12: Holding Roof Shell In Position Screwing Down

Carefully pull roofliner downwards.
Tighten down screw (1) on left and right.
Tightening torque: see 6AZ in 54 37 POWER CONVERTIBLE TOP .
Fig. 13: Pulling Roofliner Downwards And Screw

Tightening torque: see 11AZ in 54 37 POWER CONVERTIBLE TOP . .

2007 BMW 335i
Fig. 14: Identifying Down Screw

Open convertible top until screw (1) is accessible.
Tightening torque: see 6AZ in 54 37 POWER CONVERTIBLE TOP . .
Fig. 15: Identifying Convertible Top Until Screw

Adjusting pretension on fastener:
NOTE: Mark position of screw.
Slacken screw (1) (do not unscrew fully).
Turn locking element upwards through 0.5 mm.

2007 BMW 335i
Tighten screw (1).
Fig. 16: Identifying Slacken Screw

Check gap dimensions for convertible top. See 41 00... GAP DIMENSIONS, BODY .
Carry out leak test.
54 37... ALIGNING BASIC GAUGE
 00 9 251
 54 0 121
 54 0 122
 54 0 123
See.
IMPORTANT: Always install and remove basic gauge with 2 helpers.

To prevent damaging the basic gauge, set the gauge down only in the
transportation crate or on the vehicle side wall.
The basic gauge is a highly sensitive measuring instrument which reacts even
to light impacts with distortion.
The basic gauge must be checked for dimensional accuracy on a master gauge
after being subjected to impact or dropped.
The basic gauge stipulates the basic setting in the X-, Y- and Z- axes.
The basic gauge is absolutely essential for the following work operations:
2007 BMW 335i
 Gauging coupling fastener

 Gauging roof module bracket
Lift out cover (1) on left base plate.
Installation:
Cover (1) for base plate must be replaced after each removal.
IMPORTANT: The outer left hole in the base plate is the reference point for the following jobs.
Fig. 17: Locating Cover On Left Base Plate

Basic gauge
2007 BMW 335i
Fig. 18: Identifying Basic Gauge And Special Tool 00 9 251

NOTE: Use only special tool 00 9 251 to screw the gauge into position.
Remove butyl strip in side panel in area of basic gauge and clean with
Isohexane.
Grind off protruding soldered seams.
Re-establish corrosion protection.
Carefully position special tool 54 0 121 (cross beam) on side panel.
Connect special tool 54 0 122 (extension arm for X-axis clearance) to cross beam and left cowl panel base plate.
IMPORTANT: Insert guide pin of extension arm 54 0 122 in extreme left hole of base plate.
Connect special tool 54 0 123 (right extension arm) to cross beam and extension arm 54 0 122.
Observe tightening sequence:
1. Tighten down rear screws on basic gauge to 2 Nm.

2. Tighten down screw to connect extension arms to 2 Nm.
2007 BMW 335i
Check basic gauge for contact at all four contact points.
NOTE: On account of the body tolerances there may be on one side a gap dimension
between extension arm and body.
Do not exert any pressure on the extension arms.
Fig. 19: Locating Basic Gauge Four Contact Points

Fig. 20: Identifying Body Tolerances On One Side Gap Dimension Between Extension Arm
2007 BMW 335i
IMPORTANT: Adjustment work should be carried out by one person only.
Adjust knurled screws without exerting force.
Centre basic gauge with knurled screw to body.
Set identical value on scale on both sides (this value may differ from vehicle to vehicle because of the body
tolerances).
Signs (+ or -) must be identical on both sides.
Basic gauge must rest without play on inner side panel.
54 37... CHECKING DISTINGUISHING FEATURES, SEALING SYSTEM NEW/OLD
NOTE: The altered sealing system has universally been incorporated into production
since 03/2009, and has already been in production in the Shadow-Line
equipment specification since 01/2009.
In isolated cases from 4th quarter 07 on, vehicles may turn up with the altered
sealing system from trial runs.
Mixed installation between old and new systems will result in leaks.
1. = new (altered) sealing system

2. = old sealing system
Fig. 21: Identifying Symbols For New (Altered) Sealing System And Old Sealing System
Seal for front roof shell

2007 BMW 335i
Old:
Two filler pieces are fitted in the front area of the seal. Filler pieces can be identified by touch.
New:
Seal without filler pieces. Filler pieces cannot be identified by touching.
Fig. 22: Identifying Old Seal For Front Roof Shell

New:
The side edge of the front seal is pulled down a further 1.5 mm. Window glass retracts into this seal by a further
1.5 mm.
2007 BMW 335i
Fig. 23: Identifying Old/New Seals For Front Roof Shell

Front center roof shell seal
New:
Modified rib structure on seal.

2007 BMW 335i
Fig. 24: Identifying Old/New Front Center Roof Shell Seals

Rear center roof shell seal
New:
Additional rubber structure at rear end of seal.

2007 BMW 335i
Fig. 25: Identifying Old/New Rear Center Roof Shell Seals

Roof shell seal, rear
New:
Omission of lip at front end of seal.

2007 BMW 335i
Fig. 26: Identifying Old/New Roof Shell Seals, Rear

Soft top cover seal
Recondition shaped corner at transition of soft top cover seal to luggage compartment seal.
Cut off middle rib approx. 3-4 cm to allow water to flow off better in this area.
2007 BMW 335i
Fig. 27: Identifying Old/New Soft Top Cover Seals

54 37... CHECKING ROOF SHELL SEAL FOR LEAKS
Cover capping and place collecting container underneath.
Fig. 28: Placing Collecting Container Underneath And Cover Capping

Middle roof shell seal at corner of case:

2007 BMW 335i
Partially check corner of case with water bottle.
Raise sealing lip slightly.
Squirt water at base.
Fig. 29: Checking Corner Of Case With Water Bottle

Middle roof shell seal at S-bend:
Partially check at S-bend with water bottle.
Fig. 30: Checking S-Bend With Water Bottle

Check whether water is present in pocket.

2007 BMW 335i
NOTE: Middle roof shell is leaking if water is present in pocket.
Fig. 31: Checking Whether Water Is Present In Pocket

Middle roof shell seal at corner of case:
Partially check corner of case with water bottle.
Fig. 32: Checking Corner Of Case With Water Bottle

Middle roof shell seal at hinge channel:
Partially check seat at hinge channel with water bottle.

2007 BMW 335i
Fig. 33: Checking Seat At Hinge Channel With Water Bottle

Check whether water is present in pocket.
NOTE: Middle roof shell is leaking if water is present in pocket.
Fig. 34: Checking Whether Water Is Present In Pocket

Cowl panel seal in A-pillar area:
Squirt water at base with water bottle and check for leaks.
NOTE: A-pillar seal is leaking if water is present on inside of marking.

2007 BMW 335i
Fig. 35: Checking A-Pillar Seal For Water Present On Inside Of Marking
54 37... CONVERTIBLE TOP ASSEMBLY POSITION
Move convertible top so that angle of hinges is greater than 90°.
Fig. 36: Identifying Convertible Top Angle

IMPORTANT: Risk of damage! Pressure in hydraulic system drops and convertible top loses
its position.
Support rear roof shell to convertible top cover with suitable auxiliary material, e.g. hard foam.
Rear roof shell is supported by auxiliary material on convertible top cover.
Auxiliary material must lie over wide area and over entire length.
Select auxiliary material with a smooth surface, as otherwise pressure points in the outer skin and seal may
arise.
2007 BMW 335i
Roof shells block each other.
Fig. 37: Locating Convertible Top Position

54 37... CONVERTIBLE TOP SERVICE POSITIONS
 54 0 170
Work step service position for convertible top:
 Partially remove roofliner for roof shell at rear
Move convertible top into position.
Move convertible top cover so that angle of hinges is approx. 100°.

2007 BMW 335i
Fig. 38: Identifying Convertible Top Cover Angle

NOTE: Remove roof hinge bracket with a 2nd person helping.
Release screws (1) on roof hinge bracket (2).
Tilt roof shell forwards over center of gravity.
Fig. 39: Identifying Roof Hinge Bracket And Screws

IMPORTANT: Secure roof shell with cable tie (1) in order to prevent roof shell from tilting
over.
Fig. 40: Secure Roof Shell With Cable Tie

2007 BMW 335i
Fig. 41: Identifying Hooks And Special Tool 54 0 170

NOTE: Picture shows roofliner removed for purposes of clarity.

Protect roofliner against damage and dirt.
Suspend special tool 54 0 170 with hooks as follows in front frame and rear roof shell:
 Suspend hooks (2) in rear roof shell.

 Suspend hook (1) with opening pointing outwards in front frame.
NOTE: Hooks (1) can otherwise slip out of frame.
Feed and tensioning strap and tighten down.
54 37... GAUGING BASE PLATE (COWL PANEL FASTENER)
 54 0 110
2007 BMW 335i
NOTE: Cowl panel gauge to be used only after:
 Accident repairs to the cowl panel

 Removal and installation of base plate
Trim strips on cowl panel must be fitted (reference point for adjustment).
IMPORTANT: Observe body gap dimensions for ideal adjustment of convertible top in
relation to body.
Always install and remove the cowl panel gauge with 2 helpers.
To prevent damaging the cowl panel gauge, set the gauge down only in the
transportation crate or on the cowl panel.
The cowl panel gauge is a highly sensitive measuring instrument which reacts
even to light impacts with distortion.
The cowl panel gauge must be checked for dimensional accuracy on a master
gauge after being subjected to impact or dropped. See 41 00... GAP
DIMENSIONS, BODY .
Lift out cover (1) on left and right base plate.
Installation:
Cover (1) for base plate must be replaced after each removal.
Fig. 42: Lifting Out Cover On Base Plate

Gauge, cowl panel

2007 BMW 335i
Fig. 43: Base Plate On Cowl Panel With Special Tool 54 0 110
NOTE: Base plates must be screwed down loosely for gauging.

Base plates should still be able to be slid in order to center themselves.
Position special tool 54 0 110 with journal in base plate on cowl panel.
Bring gauge with stop for X- and Z-axes into contact with cowl panel.
2007 BMW 335i
Fig. 44: Bring Gauge With Stop For X- And Z-Axes Into Contact With Cowl Panel
Fig. 45: Locating Adjusting Screws And Centre Cowl Panel Gauge
IMPORTANT: Adjustment work should be carried out by one person only.
Adjust adjusting screws without exerting force.
Cowl panel gauge must rest without play on cowl panel trim strips (partially only point contact).
Centre cowl panel gauge by means of adjusting screw to cowl panel (alignment of Y-axis).
In this way, the base plates are positioned with respect to the vehicle.
Set identical value on scale on both sides (this value may differ from vehicle to vehicle because of the body
tolerances).
Signs (+ or -) must be identical on both sides.
Installation:
2007 BMW 335i
Screw down base plates on cowl panel.
The windscreen cowl panel gauge can be raised in the Z-direction by screwing down the base plates (gap
dimension between cowl panel gauge and cowl panel). This gap dimension cannot be adjusted and is thus
permissible.
54 37... GAUGING COUPLING FASTENER (AFTER REMOVING AND INSTALLING ROOF

MODULE)
 00 9 251
 00 9 450
 54 0 130
 54 0 131
 54 0 132
 54 0 180
IMPORTANT: To prevent damaging the coupling fastener gauge, set the gauge down only in
the transportation crate or on the cross beam.
The coupling fastener gauge is a highly sensitive measuring instrument which
reacts even to light impacts with distortion.
The coupling fastener gauge must be checked for dimensional accuracy on a
master gauge after being subjected to impact or dropped.
NOTE: The coupling fastener must be gauged after each removal and installation of the
roof module.
 roof module must be installed

 Align basic gauge
IMPORTANT: Tape off corners of roof shell 1 and 3. Risk of damage when positioning gauge
for coupling fastener and assembly.
2007 BMW 335i
Fig. 46: Tape Off Corners Of Roof Shell

Gauge, coupling fastener
Fig. 47: Locating Gauge, Coupling Fastener And Rubber Stop

NOTE: Coupling fastener must not be screwed into place for adjustment work (barrel
screws move freely).
2007 BMW 335i
Slacken screw for rubber stop (1) and pull back.
Insert special tool 54 0 130 in coupling fastener.
Screw gauge for coupling fastener 54 0 131 on left and 54 0 132 right onto basic gauge with special tool 00 9
251.
Fig. 48: Locating Screw Gauge For Coupling Fastener

Turn L-piece (2) under stop screw (3) of coupling fastener.
Adjust coupling fastener as follows:
Set stop screw (3) with adjusting screw (1) such that it comes up against stop (4).
 Stop screw (3) of the coupling fastener is aligned flush at stop (4)
 The L-piece (2) should ideally rest against the gauge
Bring barrel screws into contact with special tool 54 0 180 in conjunction with 00 9 450.
Tightening torque: 0.2 Nm (=20 cNm).

2007 BMW 335i
Fig. 49: Identifying Adjusting Screw And Stop Screw With L-Piece
Installation:
Observe screwing sequence of coupling fastener:
Refer to installing the roof module.
1. Z-direction (coupling fastener to screwing plate, rollover protection system)

2. Y-direction (coupling faster to side panel)
3. X-direction (roof frame to partition wall)
54 37... GAUGING COUPLING FASTENER (WITHOUT REMOVING AND INSTALLING ROOF

MODULE)
 00 9 251
 00 9 450
 54 0 130
 54 0 131
 54 0 132
 54 0 180
 54 0 190
IMPORTANT: To prevent damaging the coupling fastener gauge, set the gauge down only in
the transportation crate or on the cross beam.
The coupling fastener gauge is a highly sensitive measuring instrument which
2007 BMW 335i
The coupling fastener gauge must be checked for dimensional accuracy on a

master gauge after being subjected to impact or dropped.
NOTE: Gauging of coupling fastener must be checked.
 Roof module must be installed

 Remove panel for luggage compartment partition . See 51 47 140 REMOVING AND
INSTALLING/REPLACING PANEL FOR LUGGAGE COMPARTMENT PARTITION .
 Remove air outlet grille trim . See 51 46 026 REMOVING AND INSTALLING OR REPLACING
FRONT AIR OUTLET TRIM GRILLE
 Remove window cavity cover strip . See 51 37 240 REMOVING AND INSTALLING OR
REPLACING OUTER WINDOW CAVITY COVER STRIP FOR DOOR WINDOW, REAR
LEFT OR RIGHT
 Remove side trim upper section . See 51 43 012 REMOVING AND INSTALLING/REPLACING
REAR LEFT OR RIGHT UPPER SIDE TRIM SECTION
 Tape off corners of roof shell 1 and 3. Risk of damage when positioning gauge for coupling fastener.
NOTE: Close convertible top (roof module extended).
Slacken lock nut with special tool 54 0 190.
Turn barrel screws back with special tool 54 0 180.
Installation:
Tighten barrel screws with special tool 54 0 180 in conjunction with 00 9 450.

2007 BMW 335i
Fig. 50: Identifying Barrel Screws

NOTE: Open convertible top (roof module lowered).
IMPORTANT: Tape off corners of roof shell 1 and 3. Risk of damage when positioning gauge
for coupling fastener and assembly.
Fig. 51: Tape Off Corners Of Roof Shell

Remove holder on left and right.

2007 BMW 335i
Fig. 52: Identifying Holder And Screws


Slacken lock nuts (1) with special tool 54 0 190.
Turn barrel screws back with special tool 54 0 180.
Installation:
Tighten barrel screws with special tool 54 0 180 in conjunction with 00 9 450.
Tightening torque 0.2 Nm (= 20 cNm):

2007 BMW 335i
Fig. 54: Slacken Lock Nuts

Release screws (1) on left and right coupling fasteners.
Fig. 55: Identifying Screws On Coupling Fasteners

Installation:
Bushing (1) stretches as screw (2) is tightened against coupling fastener (3).

2007 BMW 335i
Fig. 56: Bushing Stretches As Screw Is Tightened Against Coupling Fastener

Gauge, coupling fastener
NOTE: Coupling fastener must not be screwed into place for adjustment work (barrel
screws move freely).
Slacken screw for rubber stop (1) and pull back.

2007 BMW 335i
Fig. 57: Slacken Screw For Rubber Stop (1) And Pull Back
Insert special tool 54 0 130 in coupling fastener.
Screw gauge for coupling fastener 54 0 131 on left and 54 0 132 right onto basic gauge with special tool 00 9
251.
Fig. 58: Locating Screw Gauge For Coupling Fastener

Turn L-piece (2) under stop screw (3) of coupling fastener.
Adjust coupling fastener as follows:
Set stop screw (3) with adjusting screw (1) such that it comes up against stop (4).
 Stop screw (3) of the coupling fastener is aligned flush at stop (4)
 The L-piece (2) should ideally rest against the gauge

2007 BMW 335i
Fig. 59: Identifying Adjusting Screw And Stop Screw With L-Piece
Installation:
Refer to installing the roof module.

54 37... GAUGING REAR MODULE
 00 9 450
 54 0 150
 54 0 151
 54 0 152
 54 0 180
IMPORTANT: The rear module brackets are gauged and the screw connection sealed at the
factory.
Gauging of the brackets is only to be carried out after a repair to the body.
It is necessary in the warranty period to consult the country-specific hotline
before opening the screw connection seal.
Always install and remove rear module gauge with 2 helpers.
To prevent damaging the rear module gauge, set the gauge down only in the
2007 BMW 335i
transportation crate or on brackets.

The rear module gauge is a highly sensitive measuring instrument which reacts
even to light impact with distortion.
The rear module gauge must be checked for dimensional accuracy on a master
gauge after being subjected to impact or dropped.
 Gauge roof module bracket
Tighten down rear module bracket (1) with suitable screws to special tool 54 0 150.
Turn back all barrel screws on rear module bracket (1) and check for ease of movement.
Fig. 60: Locating Rear Module Bracket With Screws

Gauge, bracket, rear module
NOTE: In order to gauge the rear module bracket, the roof module bracket must be
gauged.
Adjustment work should be carried out by one person only.
Left gauge: 54 0 151
Right gauge: 54 0 152
Place special tool, with rear module bracket screwed, over centering pin.
Insert centering pin (2) in gauge and screw down.
Screw gauge with nut (1) to bracket for roof module.

2007 BMW 335i
Fig. 61: Screw Gauge With Nut (1) To Bracket For Roof Module
Using special tool 54 0 180 in conjunction with 00 9 450, turn all barrel screws (1) until contact is made with
body.
Screw down bracket with shims.
Release screw connection (1) for gauge on rear module bracket.

2007 BMW 335i
Fig. 62: Release Screw Connection (1) For Gauge On Rear Module Bracket
Release screw connections for gauge on roof module bracket.
Remove rear module bracket gauge.
Fig. 63: Release Screw Connections For Gauge On Roof Module Bracket
54 37... GAUGING ROOF MODULE BRACKETS
 00 9 251
 00 9 450
 54 0 140
 54 0 141
 54 0 142
 54 0 143
2007 BMW 335i
 54 0 180
IMPORTANT: The roof module brackets are gauged and the screw connection sealed at the
factory.
Gauging of the brackets is only to be carried out after a repair to the body.
It is necessary in the warranty period to consult the country-specific hotline
before opening the screw connection seal.
IMPORTANT: Always install and remove roof module gauge with 2 helpers.
To prevent damaging the roof module gauge, set the gauge down only in the
transportation crate or on brackets.
The roof module gauge is a highly sensitive measuring instrument which
The roof module gauge must be checked for dimensional accuracy on a master
gauge after being subjected to impact or dropped.
Gauge, bracket, roof module
NOTE: Do not position special tool on basic gauge yet.
Mount special tool kit 54 0 140.
Connect left gauge 54 0 141 and right gauge 54 0 142 to cross strut 54 0 143.
Fig. 64: Identifying Left/Right Gauge With Special Tool 54 0 141 And 54 0 142 To 54 0 143
2007 BMW 335i
Fig. 65: Identifying Brackets For Roof Module To Special Tool 54 0 140
Attach brackets (1) for roof module to special tool 54 0 140.
Left gauge: 54 0 141
Right gauge: 54 0 142
Turn barrel screws (2) back and check for ease of movement.
NOTE: Use only special tool 00 9 251 to screw the gauge into position.
Tighten down screws to 2 Nm.

2007 BMW 335i
Fig. 66: Identifying Brackets And Barrel Screws

Carefully position roof module bracket gauge on basic gauge and screw to special tool 00 9 251.
1. Tighten down front screws on basic gauge to 2 Nm.

2. Tighten down rear screws on basic gauge to 2 Nm.
Screw roof module bracket on basic gauge crosswise in specified sequence (1 to 4) with torque wrench.
2007 BMW 335i
Fig. 67: Locating Screw Roof Module Bracket On Basic Gauge Crosswise In Sequence
Fig. 68: Identifying Special Tool 54 0 180

NOTE: Adjustment work should be carried out by one person only.

Carry out following tasks only with special tool 54 0 180 in conjunction with 00 9
450.
2007 BMW 335i
Tighten down barrel screws to 0.05 Nm (=5 cNm).
1. Barrel screw, rear left

2. Barrel screw, rear right
3. Barrel screw, front left
4. Barrel screw, front right
Screw down bracket with shims.
Release screw connection (1) for gauge on bracket.
Release screw connection for roof module bracket gauge on basic gauge.
Remove bracket gauge for roof module.
Fig. 69: Identifying Screw Connection For Gauge On Bracket

54 37... INSTALLING GUIDE PLATE FOR COWL PANEL BASEPLATE (BUILD DATE UP TO
07/2007)
 Remove cowl panel trim . See 51 44 150 REPLACING TRIM FOR FRONT ROOFLINER .
Release screw (1).

2007 BMW 335i
Fig. 70: Identifying Screw (1)

Pull back microswitch lever (3).
Mount guide plate (2) loose with screw (1).
Fig. 71: Mount Guide Plate (2) Loose With Screw (1)
Align guide plate (2) with 6.5 mm dia. dowel pin (or drill bit shank).
Tighten screw (1).

2007 BMW 335i
Fig. 72: Locating Guide Plate With Dowel Pin And Screw
Carry out visual inspection from above.
Guide plate aligned uniformly to bore.
Fig. 73: Identifying Guide Plate Dimension

54 37... LOWERING INNER HEADLINING FOR ROOF SHELL, MIDDLE
 51 0 310
Installation:
 Microencapsulated screws (Loctite) must be replaced and may not be reused

 Screw connection must be completed within 20 min. (start of curing)
2007 BMW 335i

 Thread of nut must be cleaned beforehand in event of repeated use
Move convertible top into service position.
Move convertible top so that angle of hinges is not < or =90°.
its position.
Support rear roof shell to convertible top cover with suitable auxiliary material.

Tie a safety knot into tensioning strap on left and right to prevent the tensioning strap from coiling up.
IMPORTANT: Release safety knot after installation.

2007 BMW 335i
Fig. 75: Identifying Tensioning Strap

Release retainers (2) with screwdriver and pull roof liner (1) off roof shell.
Installation:
Retainers (2) must not be damaged and must be pre-installed.
Check that roofliner is firmly seated. If necessary, bend retainers closed prior to installation.
Fig. 76: Pulling Roof Liner Off Roof Shell

Unclip roof liner at front with special tool 51 0 310.
Installation:

2007 BMW 335i
Fig. 77: Unclip Roof Liner At Front With Special Tool 51 0 310
Unclip roof liner at rear with special tool 51 0 310.
Installation:
Fig. 78: Roof Liner At Rear With Special Tool 51 0 310

Pull tensioning strap completely out of automatic reel.
Tie a safety knot into tensioning strap to prevent the tensioning strap from coiling up.
Unscrew nuts (1).

2007 BMW 335i
Installation:
Replace compression nuts.
Fig. 79: Identifying Automatic Reel And Nuts

Remove automatic reel (2).
Lower roofliner and stow in vehicle.
41 00... PROCEDURE FOR FOLDING HARDTOP AFTER AN ACCIDENT
See PROCEDURE FOR FOLDING ROOF AFTER AN ACCIDENT (CONVERTIBLE) .
54 37... REMOVING AND INSTALLING/REPLACING ALL ROOF SHELLS
Only ever replace roof shells individually in succession.
Installation:
After replacing each individual roof shell, always adjust each roof shell completely and check the folding roof
for leaks.
This procedure is the only way of ensuring that no adjustment errors are carried over to the next roof shell.
Only when the folding roof is functionally and visually problem-free again can you proceed to replace the next
roof shell.
Adhere to the procedure described below without fail.
Any deviations from this procedure will result in irreparable damage to the roof mechanism.
2007 BMW 335i
Sequence:
1. Roof shell, middle

2. Roof shell, front
3. Roof shell, rear
54 37... REMOVING AND INSTALLING/REPLACING REAR ROOF SHELL FASTENER
 Support convertible top compartment lid in service position

 Remove rear roofliner
Installation:

NOTE: Before removing, mark position of screws to ensure correct alignment when
installing.
Release screws (1).
Fig. 80: Release Screws

Replacement only:
2007 BMW 335i
Slide locking element upwards fully and screw on loosely.
Locking element should still be able to be slid in order to center itself.
Install roof shell without roofliner.
Locking element glides into place.
Open convertible top.
Adjusting pretension on fastener:
NOTE: Mark position of screw.
Slacken screw (1) (do not unscrew fully).
Turn locking element upwards through 0.5 mm.
Tighten screw (1).
Fig. 81: Slacken Screw, Turn Locking Element Upward

Check gap dimensions of roof shell and trim strip. See 41 00... GAP DIMENSIONS, BODY .
54 37... REMOVING AND INSTALLING/REPLACING GAS PRESSURIZED PROP ON LEFT OR

2007 BMW 335i
RIGHT MAIN MOUNT
 Remove panel for main bearing
Make a written record of the alignment of gas pressure spring (1) before removing.
Slide retaining springs (2) to end of gas pressurized prop (1) and lever gas pressurized prop (1).
Repeat procedure at other end of gas strut (1).
Installation:
Check that retaining spring is fitted correctly and replace if necessary.
Fig. 82: Sliding Retaining Springs To End Of Gas Pressurized Prop And Lever Gas Pressurized Prop
Place special tool 54 0 210 on both ends of gas pressurized prop (1) and lightly tighten screw (2).
Remove gas pressurized prop from the ball heads.
Mark length of tensioned gas pressurized prop with felt pen on special tool 54 0 210.
The tension in the gas pressurized prop can be completely relieved by releasing screw (2).
Repeat procedure on right-hand side of car.
Installation:
Always replace gas pressurized props in pairs.
Tension gas pressurized prop up to marking and install.

2007 BMW 335i
Fig. 83: Identifying Gas Pressurized Prop, Special Tool 54 0 210, And Screw
54 37... REMOVING AND INSTALLING/REPLACING TRIM FOR SUPPORT TUBE IN LUGGAGE

COMPARTMENT ON LEFT OR RIGHT
Release clips (1).
Installation:
Fig. 84: Feed Out Panel In Direction And Clips

54 37... REMOVING BUTYL

2007 BMW 335i
 00 9 321
Following parts are required (refer to Electronic Parts Catalogue ETK):
 Adhesive tape 83 19 9 410 979

 Adhesive cleaner 83 11 0 009 712
Press out excess butyl with fishbone 00 9 321 under seal (1).
Fig. 85: Press Out Excess Butyl With Fishbone 00 9 321 Under Seal
Stick adhesive strip (1) onto butyl and press down gently with fishbone 00 9 321.
IMPORTANT: Risk of paintwork damage!
Fig. 86: Identifying Stick Adhesive Strip

Pull off adhesive strip (1).

2007 BMW 335i
If necessary, repeat procedure with new adhesive strip until butyl is removed.
Fig. 87: Identifying Adhesive Strip

Remove butyl remnants between seal and roof outer skin with toothpick (1).
Slide toothpick (1) approx. 5 mm deep under seal. Butyl sticks to the toothpick when the latter is turned. After a
few turns, pull out toothpick and scrape off butyl.
Repeat procedure if necessary.
Clean painted surfaces with adhesive cleaner.
IMPORTANT: Adhesive cleaner attacks paint surfaces if allowed to act on surface for an
extended period of time!
Fig. 88: Identifying Toothpick

54 37 005 REPLACING FRONT ROOF SHELL SEAL

2007 BMW 335i
 00 9 470
Installation:
 Screws with sealing compound must be replaced and must not be reused
 Thread of nut must be cleaned beforehand
New parts required:
 Seal
 Butylene thread dia. 4 mm and dia. 7 mm
 Butylene flat tape 1.5 mm x 15 mm
Measure gap dimensions in following areas with special tool 00 9 470:
A. between roof shell and trim strip

B. between front and middle trim strips
Note down gap dimensions.
Fig. 89: Measuring Gap Dimensions With Special Tool

 Move into assembly position

 Bring vehicle to garage/workshop temperature

2007 BMW 335i

Remove seal from roof shell.
Fig. 91: Identifying Roof Shell Left And Right Screws

On-the-job safety
Remove remnants of adhesive from roof shell.
Clean adhesive area with Isohexane.
Air drying time: > or = 1 minute

2007 BMW 335i
IMPORTANT: Adhesive area must be dry and free from dust and grease.
Use 4 mm and 7 mm dia. butylene thread (see BMW Parts Service).
Use 1.5 mm x 15 mm butylene flat tape (see BMW Parts Service).
Overview of butylene thread laying on front roof shell, side:
1. Apply 4 mm dia. butylene thread up to middle of threaded bushes in sheet metal groove.
2. Laying on front roof shell area, see below.
3. Laying on rear roof shell area, see below.
Butylene thread resting on threaded bushes.
Fig. 92: Identifying Butylene Thread Laying On Front Roof Shell

Overview of butylene flat tape application on front roof shell corner, left/right:
1. Apply butylene flat tape approx. 3 cm in length to roof shell corner on each side.
2007 BMW 335i
Fig. 93: Identifying Butylene Flat Tape On Front Roof Shell Corner, Left/Right
Overview of butylene thread laying on front roof shell, rear left/right:
1. Apply 7 mm dia. butylene thread from middle of threaded bush rising slightly up to elongated hole.
2. Allow butylene thread to run out thinner closed around elongated hole.
Fig. 94: Identifying Butylene Thread Laying On Front Roof Shell, Rear Left/Right
Overview of butylene thread laying on front roof shell, rear left/right:
1. Apply 7 mm dia. butylene thread from middle of threaded bushes rising slightly.
Installation:
Connect and smooth butylene thread joints with plastic wedge.

2007 BMW 335i
Fig. 95: Identifying Butylene Thread Laying On Front Roof Shell, Rear Left/Right
Overview of butylene thread laying on front roof shell, front left/right:
1. Butylene flat tap on roof shell corner.

2. Apply 7 mm dia. butylene thread from middle of threaded bush rising slightly up to seal carrier.
Installation:
Connect and smooth butylene thread joints with plastic wedge.
Fig. 96: Identifying Butylene Thread Laying On Front Roof Shell, Front Left/Right
Overview of butylene thread laying on front roof shell, front left/right:
1. Butylene flat tap on roof shell corner.

2. Allow 7 mm dia. butylene thread to run out from middle of threaded bush rising slightly up to seal carrier.
2007 BMW 335i
Fig. 97: Identifying Butylene Thread Laying On Front Roof Shell, Front Left/Right
Installation:
A second person will be need to help install the seal.
Position seal at front corner on left and right of roof shell.
Align seal with screw fastening point (1) to thread in roof shell.
Press seal down in front area.
Fig. 98: Aligning Seal With Screw Fastening Point To Thread In Roof Shell
Installation:
Press seal down at side.
Carry over noted gap dimensions and screw down seal.

2007 BMW 335i
Fig. 99: Measuring Gap Dimensions

Press seal (1) down at rear left and right at sealing bead and pop into roof shell.

Check retraction depth of windows and adjust if necessary.
Carry out leak test .
54 37 015 REPLACING MIDDLE ROOF SHELL SEAL (WITH CLOSED CORNERS)
IMPORTANT: Sealing systems with different production dates are installed.
Mixed installation is not permitted!

2007 BMW 335i
See Distinguishing features, sealing system.
The following repair instructions apply to roof shells with closed corners (1) only .
For roof shells with open corners, see Replacing middle roof shell seal (with open corners).
Fig. 101: Identifying Closed Corners

Installation note:
New parts required:
 Butyl rope Ø 4 mm 83 22 2 159 535

 Butyl rope Ø 7 mm 83 19 0 416 659
Removing the seal:
Move soft top into position shown in Fig. 102.

2007 BMW 335i
Fig. 102: Moving Soft Top Into Position

Fig. 103: Identifying Screw At Rear Left

Move soft top to service position.
Release the side of the interior roof lining (1) with a folding tool 00 9 321.
Installation note:
Retainers must not be damaged and must be pre-installed on headliner.

2007 BMW 335i
Fig. 104: Detaching Headliner

Fig. 105: Releasing Left And Right Screws

Heat seal to approx. 60 °C with hot air blower.
Loosen the front and back of the seal (1) with a folding tool 00 9 321 and thread out.
Remove the seal with a helper.
Remove butylene remnants from roof shell.

2007 BMW 335i
Fig. 106: Detaching Outer Third Of Seal

On-the-job safety:
Clean adhesive area with adhesive remover.
Air drying time: = 1 minute
Prepare butyl rope dia. 4 mm, 50 mm long.
Affix butyl rope (1), starting at threaded bush. Completely close gap with butyl rope.
Fig. 107: Affixing Butyl Rope

2007 BMW 335i
Prepare butyl rope dia. 4 mm.
Affix butyl rope dia. 4 mm at area (1) along entire length of roof shell.
Affix butyl rope dia. 7 mm at area (2).
Fig. 108: Affixing Butyl Rope At Areas Specified

Affix butyl rope in area (1).


2007 BMW 335i
Fig. 110: Affixing Butyl Rope Starting At Threaded Bush

Affix butyl rope (1) at radius.
Fig. 111: Affixing Butyl Rope At Radius

Affix butyl rope (1) and cut off excess butyl.

2007 BMW 335i


Affix butyl rope in area (1) and cut off excess butyl. Make sure butyl rope (1) is correctly positioned in radius of
roof shell (2).
2007 BMW 335i
Fig. 114: Affixing Butyl Rope Correctly Positioned In Radius Of Roof Shell
IMPORTANT: Risk of leak.
Connect and smooth all butt joins of butyl ropes.
Installing the seal:
A second person will be needed to help install the seal.
Set seal in place at front and rear and adjust it sideways to correct position. Ensure that gasket is correctly
seated.
Loosely install new screws.
Complete and close the roof.
Align seal flush at front and rear and tighten screws to secure. Check gap dimensions.
2007 BMW 335i

Tighten screws (1) at rear left and right.
Fig. 116: Identifying Screws At Rear Left And Right

Checks:
 Check seal for butyl squeeze-out. If possible, allow vehicle to stand for several hours with closed roof.
Repeat test.
If squeezed out, remove butyl.
 Check that screws are secure. Make sure there is no gap between screw head and seal.
 Carry out leak test. Secure hose to roof and allow water to run over the area in question for 20 minutes.
54 37 015 REPLACING MIDDLE ROOF SHELL SEAL (WITH OPEN CORNERS)

2007 BMW 335i
IMPORTANT: Sealing systems with different production dates are installed.
Mixed installation is not permitted!
See Distinguishing features, sealing system.
The following repair instructions apply to roof shells with open corners (1) only .
For roof shells with closed corners, see Replacing middle roof shell seal (with closed corners).
Fig. 117: Identifying Open Corners

Installation note:
New parts required:
 Butyl rope Ø 4 mm 83 22 2 159 535

 Butyl rope Ø 7 mm 83 19 0 416 659
 Butyl flat tape 1.5 mm x 15 mm 83 19 0 153 321
Removing the seal:

2007 BMW 335i


Move soft top to service position.
Release the side of the interior roof lining (1) with a folding tool 00 9 321.
Installation note:

2007 BMW 335i


Loosen the front and back of the seal (1) with a folding tool 00 9 321 and thread out.
Remove the seal with a helper.
Remove butylene remnants from roof shell.

2007 BMW 335i

On-the-job safety:
Affix butyl rope (1), starting at threaded bush.

2007 BMW 335i


Affix butyl tape (1), starting at threaded bush.

2007 BMW 335i
Fig. 126: Identifying Butylene Flat Tape Laying On Rear Roof Shell Corner, Left/Right

Affix butyl rope (1).

2007 BMW 335i

Prepare butyl rope dia. 4 mm, 150 mm long

roof shell (2).
Apply the Butyl on the right side of the vehicle in the same manner as the left side.
2007 BMW 335i
seated.
Complete and close the roof.
2007 BMW 335i

Tighten screw (1) at rear left and right.

Checks:
Repeat test.
54 37 025 REPLACING REAR ROOF SHELL SEAL

2007 BMW 335i
 00 4 430
 51 0 300
Installation:
New parts required:
 Seal
 Butylene thread dia. 4 mm
 Remove roof lining .

 Move into assembly position
 Bring vehicle to garage/workshop temperature
Release screws (1).
Release screw (2) with special tool 00 4 430.
Pull seal off roof shell at rear.
Fig. 133: Identifying Roof Shell Screws

On-the-job safety
2007 BMW 335i
Remove remnants of adhesive from roof shell.
Clean adhesive area with Isohexane.
Air drying time: > or = 1 minute
Use 4 mm dia. butyl bead (see BMW Parts Service).
Overview of butyl bead laying on roof shell, front:
1. Apply butylene bead with dia. 4 mm ±1 mm with a length of at least 40 mm in sheet metal bead.
2. Apply butylene bead with dia. 4 mm ±1 mm above push pin bores.
3. Apply butylene bead with dia. 4 mm ±1 mm with a length of 70 mm in center of flange to roof shell.
Fig. 134: Identifying Butyl Bead Laying On Roof Shell, Front

Installation:
Press seal with trim strip (1) firmly onto roof shell.
Align screw fastening point to thread in roof shell.

2007 BMW 335i
Fig. 135: Identifying Trim Strip

Installation:
Press seal onto butyl bead
Pop in seal in marked area (1).
Fig. 136: Identifying Seal Marked Area

Installation:
For optimum securing of seal (2), press down entire upper area with special tool 51 0 300.
If necessary, use plastic hammer and impact protection.

2007 BMW 335i
Fig. 137: Pressing Down Entire Upper Area With Special Tool
Check retraction depth of windows and adjust if necessary.
Carry out leak test .
54 37 028 REPLACING SOFT TOP COMPARTMENT LID GASKET
IMPORTANT: To prevent water ingress, removed gaskets may not be reused.
Open rear end module.
Fig. 138: Opening Rear End Module

Release sheet screw (1) and thin sheet screw (2) on left and right.
Installation note:
2007 BMW 335i
Fig. 139: Identifying Sheet Screw And Thin Sheet Screw

Completely retract retractable hardtop and open rear cover.
Pull off gasket (1) from left to right.
Installation note:
Do not stretch, kink, or crush gasket (1)!
Coat gasket (1) with soapy water.
Perform installation from left to right (check bolting points).
Fig. 140: Pulling Off Seal

54 37 030 REPLACING BUTYL AT FRONT LEFT OR RIGHT ROOF SHELL SEAL

2007 BMW 335i
Installation note:
New parts required:
 Butyl rope Ø 4 mm 83 22 2 159 535

 Butyl rope Ø 7 mm 83 19 0 416 659
Removing the seal:
Measure gap dimensions in following areas with special tool 00 9 470 (Gap gauge):
A. between roof shell and trim strip

B. between front and middle trim strips
Note down gap dimensions.
Fig. 141: Measuring Gap Dimensions With Special Tool

 Move soft top to working position.
Release screw (1).
2007 BMW 335i

Unbutton tab (1).

IMPORTANT: Protect seal from damage by masking it off.
Release screws (1).
Remove seal at left side of vehicle.

2007 BMW 335i

Preparation:
On-the-job safety:
Remove residual butyl from roof shell and seal.
Apply butyl flat tape (1) to corner of roof shell (30 mm in length). Maintain distance of 20 mm from threaded
bush.
Fig. 145: Identifying Butylene Flat Tape On Front Roof Shell Corner, Left/Right
2007 BMW 335i
Prepare butyl rope Ø 7 mm and 250 mm in length.
Starting at seal carrier, apply butyl rope as far as threaded bushing and cut off excess butyl.
Fig. 146: Applying Butyl Rope As Far As Threaded Bushing

Apply butyl flat tape (1) to corner of roof shell (30 mm in length). Maintain distance of 20 mm (dimension a)
from threaded bushing.
Fig. 147: Applying Butyl Flat Tape To Corner Of Roof Shell

Apply butyl rope Ø 4 mm (1) around elongated hole.

2007 BMW 335i
Apply butyl rope Ø 7 mm (2) along edge.
Fig. 148: Applying Butyl Rope

Apply butyl rope with Ø 7 mm (1) and cut off excess butyl.
Fig. 149: Applying Butyl Rope With Ø 7 Mm

Apply butyl rope in area (1).

2007 BMW 335i
Fig. 150: Applying Butyl Rope In Area Specified (1 Of 3)

Apply butyl rope in area (1) and cut off excess butyl.

Apply butyl rope in area (1) and cut off excess butyl.
2007 BMW 335i

Prepare butyl rope Ø 7 mm and 500 mm in length. Apply butyl rope in area (1).
Ensure that butyl rope (1) is correctly positioned in radius of roof shell (2).
Fig. 153: Applying Butyl Rope Correctly Positioned In Radius Of Roof Shell
IMPORTANT: Risk of leaks.
Connect and smoothen all butyl rope contact points.
Fit seal starting from the front.
Align attachment point (1) of seal in relation to thread.

2007 BMW 335i
Push on seal at front and side.
Fig. 154: Aligning Seal With Screw Fastening Point To Thread In Roof Shell
Button tab (1) into roof shell.
Distribute butyl evenly beneath the tab.

Loosely screw in new bolts.
Remove support and close roof.
Align seal in a flush position at front and rear and screw in position. Check gap dimensions.
2007 BMW 335i

Checks:
 Check seal for escaping butyl. If possible, allow vehicle to stand with roof closed for several hours.
Repeat test.
Remove escaping butyl.
 Check that bolts are firmly seated. There must not be a gap between the bolt head and the seal.
 Carry out leak test. To do this, attach a hose to the roof and allow water to run over the affected area for
20 minutes.
54 37 031 REPLACING BUTYL AT SEAL, ROOF SHELL CENTER LEFT OR RIGHT (WITH
CLOSED CORNERS)
The following repair instructions apply to roof shells with closed corners (1) only .
For roof shells with open corners, see REPLACING BUTYL AT SEAL, ROOF SHELL CENTRE LEFT
OR RIGHT (WITH OPEN CORNERS).
2007 BMW 335i
Fig. 157: Identifying Closed Corners

Installation note:
New parts required:
 Butyl rope Ø 4 mm 83 22 2 159 535

 Butyl rope Ø 7 mm 83 19 0 416 659
Removing the seal:
Tape off seal, roof shell center, with adhesive tape.

2007 BMW 335i

Release screw (1) at rear left.

Move soft top to assembly position.
Detach headliner (1) at side with fishbone 00 9 321.
Installation note:

2007 BMW 335i

Release screws (1).

Detach outer third of seal (1) at front and rear with fishbone 00 9 321.
2007 BMW 335i

IMPORTANT: Protect seal from damage by masking it off.
Release screws (1).
Remove seal at left side of vehicle.

Preparation:
On-the-job safety:
2007 BMW 335i
Remove residual butyl from roof shell and seal.
Tape off sheet metal tab (1) at front and rear with adhesive tape.
Pull seal off roof panel.
Remove butyl from seal and roof shell.
Fig. 165: Taping Off Sheet Metal Tab

For better accessibility, affix seal (1) to front roof shell with adhesive tape.
2007 BMW 335i
Fig. 166: Affixing Seal To Front Roof Shell With Adhesive Tape
On-the-job safety:

2007 BMW 335i



2007 BMW 335i



2007 BMW 335i


roof shell (2).
2007 BMW 335i
Fig. 175: Identifying Roof Shell

Remove adhesive tape from sheet metal tab (1) at front and rear.
seated.
2007 BMW 335i
Fig. 176: Identifying Sheet Metal Tab


Tighten screw (1) at rear left.
2007 BMW 335i

Checks:
Repeat test.
54 37 031 REPLACING BUTYL AT SEAL, ROOF SHELL CENTER LEFT OR RIGHT (WITH OPEN
CORNERS)
The following repair instructions apply to roof shells with open corners (1) only .
For roof shells with closed corners, see REPLACING BUTYL AT SEAL, ROOF SHELL CENTRE LEFT
OR RIGHT (WITH CLOSED CORNERS).
2007 BMW 335i
Fig. 179: Identifying Open Corners

Installation note:
New parts required:
 Butyl rope Ø 4 mm 83 22 2 159 535

 Butyl rope Ø 7 mm 83 19 0 416 659
Removing the seal:
Tape off seal, roof shell center, with adhesive tape.


2007 BMW 335i

Release screw (1) at rear left.

Move soft top to assembly position.
Detach headliner (1) at side with fishbone 00 9 321.
Installation note:

2007 BMW 335i

Release screws (1).

Detach outer third of seal (1) at front and rear with fishbone 00 9 321.
2007 BMW 335i

Tape off sheet metal tab (1) at front and rear with adhesive tape.
Pull seal off roof panel.
Remove butyl from seal and roof shell.
Fig. 186: Taping Off Sheet Metal Tab

For better accessibility, affix seal (1) to front roof shell with adhesive tape.
2007 BMW 335i
Fig. 187: Affixing Seal To Front Roof Shell With Adhesive Tape
On-the-job safety:
Affix butyl rope (1), starting at threaded bush.

2007 BMW 335i


Affix butyl tape (1), starting at threaded bush.

2007 BMW 335i
Fig. 191: Identifying Butylene Flat Tape Laying On Rear Roof Shell Corner, Left/Right


2007 BMW 335i

Prepare butyl rope dia. 4 mm, 150 mm long

roof shell (2).
2007 BMW 335i
Fig. 196: Identifying Roof Shell

Remove adhesive tape from sheet metal tab (1) at front and rear.
seated.
2007 BMW 335i
Fig. 197: Identifying Sheet Metal Tab


Tighten screw (1) at rear left.
2007 BMW 335i

Checks:
Repeat test.
54 37 035 REMOVING AND INSTALLING/REPLACING ROOFLINER FOR ROOF SHELL AT

FRONT
 51 0 310
its position.
Auxiliary material must lie over wide area and if possible over entire length.

2007 BMW 335i
Fig. 200: Identifying Convertible Top Service Position

Lever out left and right clips (1).
Installation:

Lever all clips out of roofliner at front.
Installation:

2007 BMW 335i
Fig. 202: Identifying Roofliner Clips

Unclip roofliner at rear left and right from roof shell.
Installation:
Fig. 203: Identifying Retainers

Unclip roofliner in rear area with special tool 51 0 310.
Installation:

2007 BMW 335i

Installation:
Pre-install clips in roofliner (1).

54 37 040 REMOVING AND INSTALLING OR REPLACING ROOFLINER FOR ROOF SHELL IN

MIDDLE
 00 4 430
 51 0 310
 54 0 230
Installation:
2007 BMW 335i

Move soft top into service position.
Move soft top so that angle of hinges is not < or =90°.
IMPORTANT: Risk of damage! Pressure in hydraulic system drops and soft top loses its
position.
Fig. 206: Identifying Soft Top Service Position

Tie a safety knot into tensioning strap on left and right to prevent the tensioning strap from coiling up.

2007 BMW 335i
Fig. 207: Tying Safety Knot Into Tensioning Strap On Left And Right To Prevent Tensioning Strap
From Coiling Up

NOTE: Different build dates (versions) possible.
Release Torx screw (1) of reversing lug or reversing bar for tensioning cable on left and right.

2007 BMW 335i
Fig. 209: Release Torx Screw (1) Of Reversing Lug Or Reversing Bar For Tensioning Cable On Left And
Right
Release retainers (2) with screwdriver and pull roof liner (1) off roof shell.
Installation:
Fig. 210: Releasing Retainers With Screwdriver

Release Torx screw (1) of reversing lugs for tensioning cable on left and right of roof shell at rear.

2007 BMW 335i
Fig. 211: Release Torx Screw Of Reversing Lugs

Release Torx screw (1) for fastening tensioning cable on left and right of convertible top frame.
Fig. 212: Identifying Torx Screw For Fastening Tensioning Cable

NOTE: Convertible top compartment lid opened.
Using special tool 00 4 430, release Torx screw from tensioning cable mounting on main bearing.

2007 BMW 335i

Detach rubber protective sleeve (1) from spring on tensioning strap (2).
Fig. 214: Detaching Rubber Protective Sleeve From Spring On Tensioning Strap
Disengage spring (1) from tensioning strap eyelet (2).

2007 BMW 335i
Fig. 215: Disengaging Spring From Tensioning Strap Eyelet

Feed tensioning cable (1) out of reversing lug (2).
Fig. 216: Identifying Tensioning Cable And Reversing Lug

Release water valve (1).

2007 BMW 335i
Fig. 217: Identifying Water Valve

Feed out tensioning strap (1) from holder (2) for water valve and reversing lug .
Fig. 218: Identifying Tensioning Strap And Holder

Mark tensioning strap on one side before retainer.
Open retainer (1).
Replacement only:
Roof shell in middle in "closed" position, convertible top compartment lid open.
Feed tensioning strap into reversing lug and pull until roofliner contacts seal.
Turn tensioning strap over into a loop and crimp retainer (1).
2007 BMW 335i
Fig. 219: Identifying Retainer

IMPORTANT: Risk of damage to tensioning strap.
 Edges (2) must be free of sharp corners and burrs. Deburr if necessary.
 Make sure tensioning strap is correctly laid. Do not feed tensioning strap through plastic guide (1).
Fig. 220: Identifying Plastic Guide

Installation:
Replace faulty retainer.
Insert tensioning strap (1) with marking in positioner (2) of special tool 54 0 230.
If necessary, adjust measured length (see above).

2007 BMW 335i
Fig. 221: Inserting Tensioning Strap With Marking In Positioner Of Special Tool
Insert new retainer (1) in special tool 54 0 230 and crimp.
Fig. 222: Inserting Retainer In Special Tool

Feed tensioning cable (1) out of guide (2).

2007 BMW 335i
Fig. 223: Identifying Tensioning Cable And Guide

Release Torx screws (1) for C-pillar flap.
Fig. 224: Identifying Torx Screws For C-Pillar Flap

Unclip roof liner at front with special tool 51 0 310.
Installation:

2007 BMW 335i
Fig. 225: Identifying Front Roof Liner And Special Tool

Unclip roof liner at rear with special tool 51 0 310.
Installation:
Fig. 226: Identifying Rear Roof Liner And Special Tool

Pull tensioning strap completely out of automatic reel.
Tie a safety knot into tensioning strap to prevent the tensioning strap from coiling up.
Unscrew nuts (1).

2007 BMW 335i
Installation:
Replace compression nuts.
Fig. 227: Tying Safety Knot Into Tensioning Strap To Prevent Tensioning Strap From Coiling Up
Remove automatic reel (2).
54 37 045 REMOVING AND INSTALLING/REPLACING ROOFLINER FOR ROOF SHELL AT

REAR
its position.

2007 BMW 335i

Carefully insert retainer lifter between roofliner and roof shell.
Lever clips (1) out of roof shell with roof shell.
Installation:
Fig. 229: Inserting Retainer Lifter Between Roofliner And Roof Shell
Detach roofliner in area (1).

2007 BMW 335i
Fig. 230: Identifying Roofliner

Unclip roofliner at top from retainers (1).
Fig. 231: Identifying Roofliner Retainers

Pull roofliner upwards out of retainers in marked area (1).
Installation:
Make sure roofliner is correctly seated in retainers.

2007 BMW 335i
Fig. 232: Identifying Roofliner Retainers

54 37 047 REMOVING AND INSTALLING/REPLACING TRIM PANEL FOR COVER FLAP
 Open rear module partly and support it
NOTE: Shown removed here for purposes of clarity.
Release bolt of trim panel for cover flap (1) at the designated sites.
Fig. 233: Locating Cover Flap Trim Panel Bolts

2007 BMW 335i
54 37 050 REMOVING AND INSTALLING/REPLACING TRIM STRIP ON CONVERTIBLE TOP

COMPARTMENT LID
For purposes of clarity, the following operations are shown with the component removed:
 Remove trim for soft top compartment lid
Close rear module.
NOTE: Shown removed here for purposes of clarity.
Carefully unclip trim strip (1) from the soft top compartment lid and remove.
Installation:
Replace faulty clips.
Remove remains of butyl rope from trim strip and soft top compartment lid.
Fig. 234: Identifying Soft Top Compartment Lid Trim Strip

Installation:
Install new butyl rope along marking (1).
At each end, finish butyl rope in a "T" shape.

2007 BMW 335i
Fig. 235: Installing New Butyl Rope

54 37 060 REMOVING AND INSTALLING/REPLACING TRIM STRIP FOR ROOF SHELL,

MIDDLE LEFT OR RIGHT
its position.
Fig. 236: Move Convertible Top Into Service Position

2007 BMW 335i
Lever out covers of clips (1).
Fig. 237: Identifying Cover Clips

Release and remove clips (1).

Remove trim strip (2) from roof hinge bracket.
Installation:
Guide lug (1) must not be damaged.
Make sure guide lug (1) is correctly seated in roof hinge bracket.
2007 BMW 335i
Fig. 239: Identifying Lug And Trim Strip

NOTE: Secure spring wire with adhesive tape. Risk of damage!
Fig. 240: Identifying Spring Wire Adhesive Tape

54 37 065 REMOVING AND INSTALLING/REPLACING COVER FOR HINGE FOR ROOF SHELL,
MIDDLE LEFT AND RIGHT
 Remove trim strip
2007 BMW 335i
its position.

Carefully unclip cover (1) with plastic wedge.
Fig. 242: Identifying Cover

Installation:
Retainers must not be damaged and must be pre-installed.

2007 BMW 335i
Fig. 243: Locating Retainers

Installation:
Insert cover (1) with guide (2) in roof hinge bracket.
Pull cover (1) towards rear and clip into place.
Fig. 244: Identifying Cover And Guide

54 37 067 REMOVING AND INSTALLING/REPLACING HINGE
 Remove hinge cover
Installation:

2007 BMW 335i
 Screw connection must be completed within 20 mins. (start of curing)

NOTE: A helper is required for the following operations.
IMPORTANT: Tape off cover (1) of roof hinge bracket in marked area.
Risk of damage!
With a second person helping, secure roof shell at front against tilting.
Release screws (2).
Installation:
Replace microencapsulated screws.
Fig. 245: Identifying Cover Of Roof Hinge Bracket

Release nuts (1) on roof hinge bracket.
Installation:
Replace nuts.
Screw on bracket loosely.
Bracket should still be able to be slid in order to center itself.
Screw down rear nut and open convertible top.

2007 BMW 335i
Screw down front nut.
Fig. 246: Identifying Front And Rear Nut

Check gap dimensions for convertible top.
54 37 070 REMOVING AND INSTALLING/REPLACING ROOF SHELL AT FRONT
 Remove roofliner for roof shell at front
Installation:

its position.
2007 BMW 335i

Detach cable tie.
Installation:
Replace cable tie.

Release screws (1).
Remove shaper (2) from roof shell.

2007 BMW 335i
Fig. 249: Identifying Screws And Shaper

IMPORTANT: Tape off cover (1) of roof hinge bracket in marked area.
Risk of damage!
With a second person helping, secure roof shell at front against tilting.
Release screws (2).
Installation:
Turn roof hinge bracket.
Fig. 250: Identifying Cover Of Roof Hinge Bracket And Screws


2007 BMW 335i
Mark screws (1) and release.
Remove roof shell with a second person helping.

IMPORTANT: Do not adjust barrel screws.
Fig. 252: Locating Barrel Screws

NOTE: The scope of work for removing and installing the roof shell ends here.
Replacement only:
Remove locking mechanism

2007 BMW 335i
Fig. 253: Identifying Locking Mechanism

Remove seal (2) .
Release screws (1) and remove retaining strip (3) for seal.
Fig. 254: Identifying Seal, Screws And Retaining Strip

Drill out rivets (1) from guide element (2) on left and right.
Remove guide element (2).

2007 BMW 335i
Fig. 255: Identifying Rivets And Guide Element

Release screws (1).
Remove shaper (2) from roof shell.
Fig. 256: Identifying Screws And Shaper

Measure heights of all barrel screws with a depth gauge and note down.
Carry over adjustment to new roof shell.
Installation:
Insert barrel screws with Loctite.

2007 BMW 335i
Fig. 257: Identifying Heights Of Barrel Screws

54 37 075 REMOVING AND INSTALLING/REPLACING ROOF SHELL IN MIDDLE
 Lower roofliner for roof shell
(From roof shells and front and middle only)
 Remove hinge cover

 Secure SOFT Top in service position
Installation:

Carefully unclip water valve (1).

2007 BMW 335i
Fig. 258: Identifying Water Valve

Pull water valve (1) off water drain hose (2).
Fig. 259: Identifying Water Valve And Water Drain Hose

Mark tensioning strap at deflection point (1).
Carefully open retainer (2) without damaging the tensioning strap.
Installation:
Replace faulty retainer.

2007 BMW 335i
Fig. 260: Identifying Retainer

Installation:
Make sure tensioning strap is correctly laid. Do not feed tensioning strap through plastic guide (1).
Fig. 261: Identifying Plastic Guide

Feed tensioning strap (1) out of holder (3) on frame.
Open holder (3) and remove water drain hose (2).

2007 BMW 335i
Fig. 262: Identifying Holder And Water Drain Hose

Unclip metal retainer (1) from frame.
Feed water drain hose (2) out of frame.
Fig. 263: Identifying Metal Retainer And Water Drain Hose

NOTE: A second person will be needed to help with the following work steps for
removing the roof shell in the middle.
If necessary, remove roof hinge bracket:
Release nuts (1) on roof hinge bracket.
Installation:
Replace nuts.
2007 BMW 335i
Screw on bracket loosely.
Bracket should still be able to be slid in order to center itself.
Close soft top.
Screw down rear nut and open soft top.
Screw down front nut.
Fig. 264: Identifying Nuts On Roof Hinge Bracket

Remove roof shell.
NOTE: Plug connection on right roof shell cylinder can be incorrectly positioned.
The plug connection must be repositioned if it does not point to the outside of
the vehicle.
2007 BMW 335i

Replacement only:
Remove fastener, roof shell, middle (1) .
Remove seal, roof shell, middle (2) .
Fig. 266: Identifying Fastener, Roof Shell, Middle

Measure height of barrel screws for roof shell fastener and carry over to new roof shell.
Installation:

2007 BMW 335i

Measure height of barrel screws for roof shell screw fastening points and carry over to new roof shell.
Installation:

Release screw (1).
Release screw (2) on opposite side.
Remove water drain hose (3).
Installation:
Replace water drain hose.

2007 BMW 335i
Fig. 269: Identifying Water Drain Hose

Check gap dimensions for soft top.
54 37 080 REMOVING AND INSTALLING/REPLACING ROOF SHELL AT REAR
 Remove roofliner for roof shell at rear

 Measure and note down gap dimensions
Installation:

its position.

2007 BMW 335i

Unscrew left and right nuts (1).
Remove grounding strap.
Fig. 271: Identifying Grounding Strap Nuts

Roof shell, left side:
Unlock plug connections (1) on antenna amplifier and disconnect.
Unclip wiring harness.
Unlock plug connection (2) on blocking circuit and disconnect.

2007 BMW 335i
Fig. 272: Identifying Plug Connection (Left Side)

Roof shell, right side:
Fig. 273: Identifying Plug Connection (Right Side)

Unclip wiring harness (1) from roof shell.
Installation:

2007 BMW 335i
Fig. 274: Identifying Wiring Harness

NOTE: A second person is required to help in removing the roof shell.
Mark screws (1) on left and right.
Release screws (1).
Remove roof shell.
Do not adjust barrel screws on roof shell.

2007 BMW 335i
Replacement only:
Drill out rivets (2).
Remove retainers (1).
Fig. 276: Identifying Rivets And Retainers

Remove retainers (1) from roof shell.
Fig. 277: Identifying Retainers

Left side on roof shell:

2007 BMW 335i
Release nut (2) and remove blocking circuit.
Fig. 278: Identifying Plug Connection Nut

Right side on roof shell:
Release nut (2) and remove antenna amplifier.
Release nut (4) and remove blocking circuit.
Fig. 279: Identifying Plug Connection With Nut


2007 BMW 335i
Remove locking part (2).
Remove seal (3).
Fig. 280: Identifying Locking Part

Measure heights of all barrel screws (1) to roof shell with a depth gauge and note down.
Carry over adjustment to new roof shell.
Installation:

54 37 090 REMOVING AND INSTALLING/REPLACING FRONT COWL PANEL FASTENER

2007 BMW 335i
 Remove roofliner at front
Installation:

its position.
Fig. 282: Moving Convertible Top Into Service Position

Slide open retaining clip (1) and unclip ball head.
NOTE: Before removing, mark position of nuts to ensure correct alignment when
installing.
2007 BMW 335i
Unscrew nuts (2).
Tightening torque see 8AZ in 54 37 POWER CONVERTIBLE TOP .
Installation:
Replace nuts.
Fig. 283: Identifying Retaining Clip With Nuts

Replacement only:
Screw on new fasteners loosely.
Fastener should still be able to be slid in order to center itself.
Install Roof shell, front without roofliner.
Fasteners glide into place.
Tightening torque see 8AZ in 54 37 POWER CONVERTIBLE TOP .
Check gap dimensions and if necessary adjust. See 41 00... GAP DIMENSIONS, BODY .
2007 BMW 335i

54 37 105 REMOVING AND INSTALLING/REPLACING COMPLETE FRONT ROOF SHELL

FASTENER PACK
 Remove Roof shell, front

 Remove roof lining
Installation:

its position.

2007 BMW 335i

Slide open retaining clip (1) and unclip ball head.
Fig. 286: Sliding Open Retaining Clip

NOTE: Before removing fasteners, mark position of screws to ensure correct alignment
when installing.
Release screws (1).

2007 BMW 335i

NOTE: Before removing fasteners, mark position of screws to ensure correct alignment
when installing.
Release screws (1).

Do not adjust barrel screws (1) for height adjustment.
When replacing roof shell, measure height of barrel screws and carry over to new roof shell.
2007 BMW 335i

NOTE: Before removing fasteners, mark position of nuts to ensure correct alignment
when installing.
Unscrew nuts (1).
Installation:
Replace nuts.
Remove motor carrier with drive unit.
Fig. 290: Identifying Motor Carrier Nuts

Installation:
2007 BMW 335i
Guide cylinder must run into counter-support without noises and tension.
Check gap (A) and adjust if necessary.
(A) = 19 mm
Fig. 291: Measuring Middle Roof Shell Fastener To Front Roof Shell Fastener And Necessary Adjust
Gap
Installation:
The scope of work for removing and installing the front roof shell fastener pack ends here.
Replacement only:
Align new motor carrier with drive unit centrally to threaded pin.
Tighten down new nuts (1).

2007 BMW 335i
Fig. 292: Identifying Motor Carrier Nuts

Screw on new fasteners loosely.
Install roof shell without roofliner.
Installation:
Guide cylinder must run into counter-support without noises and tension.
Check gap (A) and adjust if necessary.
(A) = 19 mm
Fig. 293: Measuring Middle Roof Shell Fastener To Front Roof Shell Fastener And Necessary Adjust
Gap
2007 BMW 335i
Adjust gap (A) = approx. 19 mm.
Tighten down screws.

Installation:
Strikers must be completely closed.

2007 BMW 335i
Fig. 295: Identifying Striker Correct And Incorrect Position

NOTE: Check gap dimensions and if necessary adjust.

See 41 00... GAP DIMENSIONS, BODY .
54 37 110 REMOVING AND INSTALLING/REPLACING FASTENER FOR ROOF SHELL IN

MIDDLE
 Remove roofliner in middle
Installation:

its position.

2007 BMW 335i

installing.
Release screws (1).

NOTE: The scope of work for removing and installing the roof shell fastener ends here.
Screw on fastener loosely.

2007 BMW 335i
Fastener centers itself.
Mark screw position and open convertible top.
Slacken screws and slide center fastener 0.5 mm in opposite direction to direction of travel.
The required pretension is thus obtained.
Fig. 298: Identifying Gap Dimensions

54 37 115 REMOVING AND INSTALLING/REPLACING MIDDLE ROOF SHELL FASTENER PACK
 Remove Roof shell, middle
Installation:

2007 BMW 335i
its position.

installing.
Release screws (1).
Remove fastener.
2007 BMW 335i

NOTE: The scope of work for removing and installing the roof shell fastener pack ends
here.
Replacement only:
Screw on fastener (4) loosely.
Fastener (4) should still be able to be slid in order to center itself.
Aligning fastener (4) manually:
1. Slide fastener in X towards rear

2. Slide fastener in X 1 mm towards front
3. Centre fastener in Y
2007 BMW 335i
Fig. 301: Sliding Fastener In Towards Rear

Centre fastener (1) and screw on loosely.
Fastener (1) should still be able to be slid in order to center itself.
Fig. 302: Adjusting Still

Install Roof shell, middle without roofliner.
Fig. 303: Identifying Roof Shell Screws

2007 BMW 335i
Measure middle roof shell fastener to front roof shell fastener and if necessary adjust gap (A).
A) 19 mm
Fig. 304: Measuring Middle Roof Shell Fastener To Front Roof Shell Fastener
NOTE: Check gap dimensions and if necessary adjust. See 41 00... GAP DIMENSIONS,
BODY .
54 37 130 REMOVING AND INSTALLING ROOF MODULE
 00 9 450
 54 0 101
 54 0 102
 54 0 180
 54 0 190
 54 0 220
 Connect battery charger

 Remove panel for passenger compartment partition . See 51 47 143 REMOVING AND
INSTALLING/REPLACING PANEL FOR PASSENGER COMPARTMENT PARTITION .
 Remove luggage compartment trim panel . See 51 47 210 REMOVING AND
INSTALLING/REPLACING TRUNK TRIM PANEL ON LEFT SIDE PANEL and 51 47 220
2007 BMW 335i
REMOVING AND INSTALLING/REPLACING LUGGAGE COMPARTMENT TRIM PANEL

ON RIGHT SIDE PANEL .
 Remove air outlet trim grille . See 51 46 026 REMOVING AND INSTALLING OR REPLACING
FRONT AIR OUTLET TRIM GRILLE .
 Remove rear module.
 Remove window cavity cover strip . See 51 37 240 REMOVING AND INSTALLING OR
REPLACING OUTER WINDOW CAVITY COVER STRIP FOR DOOR WINDOW, REAR
LEFT OR RIGHT .
 Remove lower section of side trim . See 51 43 034 REMOVING AND INSTALLING/REPLACING
REAR LEFT OR RIGHT LOWER SIDE TRIM SECTION .
Move convertible top for following work into position.
Fig. 305: Moving Convertible Top For Following Work Into Position
Release screws (1).
Remove cover (2) for hydraulic unit.

2007 BMW 335i
Fig. 306: Identifying Cover Screws

Unclip all cable holders on hydraulic lines on left and right.
Fig. 307: Unclipping Cable Holders

NOTE: Only in case of optional extra with CD changer.
Slacken screws and slide CD changer back.
Fig. 308: Identifying CD Changer Screws

Unlock plug connections (1) on left in luggage compartment and disconnect.

2007 BMW 335i
Fig. 309: Identifying Plug Connections

Lever out clips (1) on left and right trim.
Remove trim (2) on right and left.
Fig. 310: Identifying Trim And Clips

Release screws (1).
Remove load protective plate on left and right.
NOTE: For right load protective plate, remove control unit if necessary. See 65 77 770
REMOVING AND INSTALLING (REPLACING) ROLLOVER CONTROLLER .
2007 BMW 335i
Fig. 311: Identifying Protective Plate Screws


Fit special tool 54 0 220 to prevent unintentional triggering of rollover
protection system.

Tightening torque: see 13AZ in 54 37 POWER CONVERTIBLE TOP ..
Slacken lock nut with special tool 54 0 190.
Turn back barrel screws by approx. 3 mm.
Installation:
2007 BMW 335i
Tighten barrel screws only with special tool 54 0 180 together with 00 9 450.
Fig. 313: Identifying Back Barrel Screws

Fig. 314: Identifying Coupling Screws

Installation:
Bushings (1) must be replaced and screwed before installation of convertible top into body up to shortly before
stop.
Bushing (1) stretches as screw (2) is tightened against coupling fastener (3).

2007 BMW 335i
Fig. 315: Identifying Bushings

Secure metal plate (1) over Hall sensor in left mounting cover (2).
Metal plate (1) simulates a closed luggage compartment partition.
Fig. 316: Identifying Metal Plate And Mounting Cover

Place both legs of special tool 54 0 101 as close together as possible.

2007 BMW 335i

Carefully insert folded special tool 54 0 101.

NOTE: The bolts have different lengths. Install bolts as follows:
1. Short bolts
2. Long bolts
Tighten down bolts on main mounts on left and right.

2007 BMW 335i
Fig. 319: Identifying Short And Long Bolts

Assemble linkage and screw down.
Adjust rotary sleeve (1) if necessary.
Fig. 320: Adjusting Rotary Sleeve

Adjust the length of the linkage with rotary sleeve (1) until the fastening point fits in the barrel screw.
IMPORTANT: Brass pin can break off.

Tightening torque for nut (2): 8 Nm.
Tighten nut (2) on left and right. The cone is secured in the barrel screw.
2007 BMW 335i
Fig. 321: Adjusting Length Of Linkage With Rotary Sleeve

Lay linkage (1) for luggage compartment partition.
Fig. 322: Laying Linkage For Luggage Compartment Partition

2007 BMW 335i
Fig. 323: Sliding Locking Sleeve Over Pivot Joint

Installation:
The assembly carrier must rest free of tension on the main mount. Otherwise stress may occur at the main
mount that could cause faulty installation.
Without using excessive force, pull tensioning rods outwards over rotary sleeves.
Slide locking sleeve (1) over pivot joint.
Secure hydraulic control unit (1) with cable ties to assembly carrier.
2007 BMW 335i
Fig. 324: Securing Hydraulic Control Unit With Cable Ties

Secure hydraulic cylinders (1) on left and right to assembly carrier with cable tie.
Fig. 325: Securing Hydraulic Cylinders On Left And Right To Assembly

Unclip cable holder (1).

2007 BMW 335i
Fig. 326: Identifying Cable Holder

Fig. 327: Identifying Roof Module Main Bearings Nuts

Release front nuts (1) on left and right roof module main bearings.

2007 BMW 335i
Open hardtop (roof module lowered) .
IMPORTANT: Tape off corners (1) of roof shells. Risk of damage when positioning gauge for
coupling fastener and assembly.
Fig. 328: Taping Corners Of Roof Shells

Remove holder on left and right.

Release screws (2) on grounding strap on left and right.

2007 BMW 335i
Fig. 330: Identifying Coupling Screws

Release lock nut (1) with special tool 54 0 190.
Turn barrel screw back.
Installation:
Fig. 331: Identifying Lock Nut

Installation:
Gauge coupling fastener.

2007 BMW 335i

Fig. 332: Identifying Roof Module Main Bearings Nuts

Release rear nuts (1) on left and right roof module main bearings.
IMPORTANT: Convertible top must not be moved after the nuts on the main bearing have
been released.
NOTE: Shown here without roof shells for a better overview.
Unlock plug connection (1) on right in luggage compartment and disconnect.

2007 BMW 335i


Detach water drain hose (1).

2007 BMW 335i
Fig. 335: Identifying Water Drain Hose And Cable Holder

Unclip cable holders.

2007 BMW 335i
Fig. 337: Lifting Roof Module With Special Tool (54 0 102)
NOTE: Carry out this part of the work with the assistance of two other persons.
Position special tool 54 0 102 with workshop crane over roof module.
IMPORTANT: Use lifting gear and assembly carrier only in conjunction with BMW WJN.10
workshop crane (special lifting arm with 1690 mm arm length - refer to BMW
Workshop Equipment Catalogue) or a crane with comparable specifications.
Feed in belts between rollover protection system and roof module.
Do not twist straps!
Attach strap to assembly carrier.
Attach rear strap to assembly carrier.
IMPORTANT: Straps must not be twisted!

2007 BMW 335i
Fig. 338: Attaching Rear Strap To Assembly Carrier

Fig. 339: Lifting Out Roof Module Carefully

To lift out the convertible top uniformly, make sure the special tool is aligned parallel to the roof module.
Lifting out roof module carefully and in stages with lifting gear.
2007 BMW 335i
Check freedom of movement of roof module with respect to body.
Carefully set roof module down on a suitable surface (e.g. squared beams on pallet).
Replacement only:
Refer to replacing roof module.
Set removed roof module down on inside of lid of transportation crate and bolt down.
Change assembly carrier to new roof module and install roof module in vehicle.
Set down removed roof module with assembly carrier from inside of transportation crate and bolt down.
Remove assembly carrier.
Fig. 340: Removing Roof Module

Installation:
Carry out diagnosis
54 37 140 REPLACING ROOF MODULE
 54 0 101

2007 BMW 335i
 Remove roof module
Fig. 341: Identifying Special Tool (54 0 101) To Roof Module

Set removed roof module down on inside of lid of transportation crate and bolt down.
Changeover special tool 54 0 101 to new roof module.
Check distanced between left and right brackets and left and right main mounts:
1. Measure distance between guide pins.

2. Measure distance between rear threaded studs.
2007 BMW 335i
Fig. 342: Measuring Distance Between Guide Pins

Check measured lengths between the main mounts.
If necessary, use rotary sleeve (1) to adjust measured distance between the guide pins.
If necessary, use rotary sleeve (2) to adjust measured distance between the threaded studs.
Fig. 343: Identifying Rotary Sleeve

Install roof module in vehicle.
Set down removed roof module with assembly carrier from inside of transportation crate and bolt down.
Remove assembly carrier.
54 37 160 REMOVING REAR MODULE

2007 BMW 335i
 00 9 450
 54 0 180
 54 0 200
 Connect charger
 Remove luggage compartment partition . See 51 47 202 REMOVING AND INSTALLING COVER
FOR LUGGAGE COMPARTMENT .
 Remove trim from rear apron . See 51 46 050 REMOVING AND INSTALLING/REPLACING
TOP TRIM ON REAR APRON .
Installation:

Open convertible top compartment lid.
Mechanically open rear lid.
Fig. 344: Opening Convertible Top Compartment Lid

IMPORTANT: Convertible top compartment lid can tilt forwards when hydraulic cylinders are
removed and must be supported with suitable apparatus.
2007 BMW 335i
Fig. 345: Removing Convertible Top Compartment Lid

Measure distance A between rear module kinematics.
Installation:
Adjust distance A.
Basic adjustment dimension e.g. for replacement:
A = 770.3 mm.
Fig. 346: Measuring Distance Between Rear Module Kinematics

Removing hydraulic cylinder for rear lid:
Release screw (1).

2007 BMW 335i
Fig. 347: Identifying Hydraulic Cylinder Screw

Slide retaining clip (1) upwards.
Detach ball socket at side.
NOTE: Close trunk lid carefully.
Fig. 348: Identifying Ball Socket Retaining Clip

Disconnect all cable ties.
Installation:
Replace faulty cable ties.

2007 BMW 335i
Fig. 349: Identifying Cable Ties

Feed hydraulic line (1) with hydraulic cylinder out of wiring harness (2).
Installation:
Make sure hydraulic line is correctly routed behind wiring harness.
Close rear lid.
Fig. 350: Identifying Hydraulic Line And Wiring Harness

Remove locating cover (2) on left and right.

2007 BMW 335i

NOTE: Operation not absolutely necessary, only if roof module still has to be
subsequently moved.
Secure metal plate (1) over Hall sensor in left mounting cover (2).
Metal plate (1) simulates a closed luggage compartment partition.
Fig. 352: Identifying Metal Plate And Mounting Cover

IMPORTANT: Observe disconnection sequence of plug connections without fail.
Plug connection (1) with locking bar must first be unlocked and disconnected.
NOTE: If the Soft Close Automatic of the rear lid opens, close plug connection again
and change disconnection sequence.
Rear lid must be closed.
2007 BMW 335i

Connect special tool 54 0 200 to vehicle-side plug for rear module.
NOTE: Adapter simulates closed rear lid. Retractable hardtop without rear lid not in
working order.
Fig. 354: Connecting Special Tool (54 0 200) To Vehicle-Side Plug For Rear Module
Unlock plug connections (1) without locking bar.
US only:
Unlock plug connection for SDARS and disconnect.

2007 BMW 335i

NOTE: Do not adjust barrel screws.
Replacement only:
Bring barrel screws into contact with special tool 54 0 180 in conjunction with special tool 00 9 450.

NOTE: Before removing, mark position of screws (1) to ensure correct alignment
during installation.
Do not release screws.
2007 BMW 335i

IMPORTANT: Proceed with the greatest possible caution when carrying out the following
tasks.
Risk of damage!
Three persons are essential for helping to carry out the following tasks.
Generously cover bumper area (loading sill) with protective covers (1).
Fig. 358: Identifying Protective Covers

IMPORTANT: Rear module sinks if incorrectly supported. Risk of damage!
Position a helper on both the left and right sides of the rear module.
Grip rear module with two hands on rear module kinematic assembly and support Z-direction.
NOTE: Bracket is double-jointed and bends.

2007 BMW 335i
Fig. 359: Griping Rear Module

With one person on other side, simultaneously release screws (1) from bearing block.
Remove rear module.
Set down rear module on a suitable surface.
IMPORTANT: Do not damage any surrounding parts.

Installation:
Carry out diagnosis.
54 37 185 REMOVING AND INSTALLING/REPLACING HYDRAULIC UNIT (DRIVE) FOR

2007 BMW 335i
RETRACTABLE HARDTOP
 Remove luggage compartment floor trim panel . See 51 47 101 REMOVING AND
INSTALLING/REPLACING LUGGAGE COMPARTMENT FLOOR TRIM PANEL .
CAUTION: Hydraulic fluid may emerge from the disconnected lines and the open
connections on the hydraulic unit (drive).
Protect components and work area with suitable materials (e.g. cloths).
Follow repair instructions for hydraulic system.
Do not fit hydraulic lines in kinked, crushed or transposed condition.
Release screws (1).

Cut open cable tie (1).
Installation:
Detach foam part from hydraulic unit.
Remove relay (2) from holder.

2007 BMW 335i
Fig. 362: Removing Relay From Holder

Installation:
Plug connections are coded against incorrect assembly.
Installation:
Order of plug connection specified by wiring harness.

Disconnecting hydraulic lines from hydraulic unit:
 Release screws and push lockplates (1) in direction of arrow.

2007 BMW 335i
 Detach hydraulic lines.

 Remove hydraulic unit (drive).
Installation:
Hydraulic lines and connections are marked with numbers to prevent mix-ups.
Check fluid level or top up if necessary.
Fig. 364: Identifying Screws And Lockplates

54 37 190 REMOVING AND INSTALLING/REPLACING LEFT HYDRAULIC CYLINDER FROM

ROOF SHELL, MIDDLE
NOTE: Except for the operations covering the plug connections for the Hall sensors,
this task is identical to:
 Removing and installing/replacing right hydraulic cylinder from roof shell,

middle.
54 37 195 REMOVING AND INSTALLING/REPLACING RIGHT HYDRAULIC CYLINDER FROM

ROOF SHELL, MIDDLE
 Remove roof lining

 Have roof module supported partially by helpers
connections on the hydraulic cylinder.
2007 BMW 335i
NOTE: Hydraulic system must be at zero pressure.

Open screw on hydraulic unit 1.5 turns.
Lever out clips (1).
Fig. 365: Identifying Hydraulic Unit Clips

Drive out bearing pins (1 and 2).
Installation:
Bearing pin (1) is shorter than bearing pin (2).
Remove hydraulic cylinder.
Fig. 366: Identifying Hydraulic Unit Bearing Pin


2007 BMW 335i
NOTE: Plug connection on right roof shell cylinder can be incorrectly positioned.
The plug connection must be repositioned if it does not point to the outside of
the vehicle.

Disconnecting hydraulic lines from cylinder:
Disconnect cable straps.
Installation:
Replace cable straps.
Slide open retaining rings (1) with screwdriver.
Detach hydraulic lines (2).
IMPORTANT: Protect joints (lines and cylinder) against dripping fluid, e.g. with a cleaning
cloth.
Observe hose markings.
Make sure airbag hydraulic lines and wiring harness are exactly routed.
2007 BMW 335i
Fig. 368: Detaching Hydraulic Lines

NOTE:  Carry out operational check.

 Check fluid level.
54 37 200 REMOVING AND INSTALLING/REPLACING LEFT COUPLING FASTENER

HYDRAULIC CYLINDER
 Removing and installing/replacing right coupling fastener hydraulic

cylinder
54 37 205 REMOVING AND INSTALLING/REPLACING RIGHT COUPLING FASTENER

HYDRAULIC CYLINDER
 Remove side trim upper section . See 51 43 012 REMOVING AND INSTALLING/REPLACING
REAR LEFT OR RIGHT UPPER SIDE TRIM SECTION .

Removing hydraulic cylinder:

2007 BMW 335i
 Slide retaining clip (1) upwards.

 Detach ball socket at side.
 Remove retaining ring (2).
 Drive through bearing pin (3).
 Feed out hydraulic cylinder.
Fig. 369: Removing Retaining Ring

Replacing hydraulic cylinder:

2007 BMW 335i

54 37 210 REMOVING AND INSTALLING/REPLACING LEFT MAIN KINEMATICS HYDRAULIC

CYLINDER
 Removing and installing/replacing right main kinematics hydraulic

cylinder
54 37 215 REMOVING AND INSTALLING/REPLACING RIGHT MAIN KINEMATICS

HYDRAULIC CYLINDER
 Remove luggage compartment wheel arch trim on left or right. See 51 47 210 REMOVING AND
INSTALLING/REPLACING TRUNK TRIM PANEL ON LEFT SIDE PANEL and 51 47 220
REMOVING AND INSTALLING/REPLACING LUGGAGE COMPARTMENT TRIM PANEL
ON RIGHT SIDE PANEL .
 Remove panel for main bearing on left or right. See 51 47 207 REMOVING AND
INSTALLING/REPLACING PANEL FOR MAIN BEARING ON LEFT OR RIGHT .
 Trunk lid opened


2007 BMW 335i

Installation:
Make sure wiring harness is exactly routed in main bearing.
Fig. 372: Identifying Wiring Harness

 Remove retaining ring (1)

 Drive out pin in inward direction (middle of vehicle)
 Detach locking clip (2)
 Drive out pin in outward direction (side of vehicle)
 Feed hydraulic cylinder out of main bearing
2007 BMW 335i
Fig. 373: Identifying Retaining Ring And Locking Clip

Disconnect all cable ties.
Installation:
Detach locking clip (1).
Release screw (2) and remove tab washer.
Detach hydraulic lines.
cloth.

2007 BMW 335i

54 37 220 REMOVING AND INSTALLING/REPLACING LEFT CONVERTIBLE TOP

COMPARTMENT LID HYDRAULIC CYLINDER
 Removing and installing/replacing right convertible top compartment lid

hydraulic cylinder
54 37 225 REMOVING AND INSTALLING/REPLACING RIGHT CONVERTIBLE TOP

COMPARTMENT LID HYDRAULIC CYLINDER
 Remove support tube trim on left or right

IMPORTANT: Convertible top compartment lid can tilt forwards when hydraulic cylinders are
removed and must be supported with suitable apparatus.
Fig. 375: Removing Convertible Top Compartment Lid

2007 BMW 335i
Open rear lid.
Release screw (1).
Installation:
Replace screw (1) and insert with Loctite.
Fig. 376: Identifying Hydraulic Cylinder Screw

 Slide retaining clip (1) upwards.

 Detach ball sockets at sides.
 Feed out hydraulic cylinder.
Fig. 377: Identifying Ball Socket Retaining Clip

2007 BMW 335i
Detach cable connectors.
Installation:
Feed out wiring harness.

cloth.
Installation:

2007 BMW 335i
Fig. 379: Sliding Open Retaining Rings

Installation:
 Carry out operational check.

 Check convertible top settings.
54 37 232 REMOVING AND INSTALLING SUPPORT BLOCK
Move roof module into following intermediate station.

NOTE: Illustration shows removal of left side.

Lever out expansion rivets (1).

2007 BMW 335i
Remove trim (2) for support block.
Fig. 381: Identifying Expansion Rivets And Trim

Unscrew nuts (1).
Remove support block.
Fig. 382: Identifying Support Block Nuts

NOTE: Observe following work steps for installing support block:
Observe screwing sequence for support block (4).
Turn banjo bolt (2) back.
Tighten nut (1).

2007 BMW 335i
Insert banjo bolt lock (2) until contact is made with body.
Tighten nut (3).
Fig. 383: Identifying Banjo Bolt Lock With Nut

Release screw (1).
Move support element (2) upwards to maximum extent.
It must still be possible to slide the support element (2).
Fig. 384: Moving Support Element Upwards To Maximum Extent


2007 BMW 335i
It must still be possible to slide the guide element (2).
Stow roof module.
Storage element (3) adjusts itself to support height.
Guide element (2) slides into correct position.
Extend roof module until support block is accessible.
Tighten screws (1) and (4).
Fig. 385: Sliding Guide Element

Installation:
Install trim for support block.
54 37 235 REMOVING AND INSTALLING/REPLACING HOLDER FOR C-PILLAR FLAP
Installation:

Release Torx screws (1) for C-pillar flaps.

2007 BMW 335i
Fig. 386: Identifying C-Pillar Flap Torx Screws

Pull off snap ring (1).
Drive out pin and remove holder with spring.
Remove tension spring.
Fig. 387: Removing Tension Spring

Overview of single parts .

2007 BMW 335i
Fig. 388: Overview Of Single Parts

54 37 240 REMOVING AND INSTALLING/REPLACING MICROSWITCH FOR BASEPLATE
 Remove cowl panel trim . See 51 44 150 REPLACING TRIM FOR FRONT ROOFLINER .
Release screws (1).
Remove microswitch (2).
Fig. 389: Identifying Microswitch Screws

For vehicles with base plate with spring package only:
IMPORTANT: When removing the microswitch protect the spring package from falling out.
2007 BMW 335i
Ensure correct seating of the 6 spring elements during installation.
Fig. 390: Identifying Correct Seating Of Spring Elements

Removing guide plate if necessary only on build date (version) up to 07/2007:
Release screw (1).
Pull back microswitch lever (3).
Remove guide plate (2).
Fig. 391: Pulling Back Microswitch Lever

54 37 245 REMOVING AND INSTALLING/REPLACING BOTH BASE PLATES
 Close the soft top and measure the gap dimension between cowl panel and roof pan in front. Note down
value.
2007 BMW 335i
 Remove cowl panel cover .
IMPORTANT: Never loosen both base plates at the same time.
Disconnect and unclip cables (1).
Release screws (2) for left base plate.
Tightening torque: 8 +/- 1 Nm
Remove left base plate.
Fig. 392: Identifying Screws And Cables

Replacement:
Release screws (1).
Tightening torque: 4, 6 +/- 0, 7 Nm
Modify microswitches (2).

2007 BMW 335i
Fig. 393: Identifying Microswitches And Screws

Installation note:
 Install left base plate. Tighten screws until the base plate can barely be moved.
 Close soft top. Float the base plate in. Tighten down screws. Compare the gap dimension with the
recorded values. If necessary, open soft top. Correct the position of the left base plate in longitudinal
direction of the vehicle and close the soft top again.
 Close soft top. Float the base plate in. Tighten down screws. Compare the gap dimension with the
recorded values. If necessary, open soft top. Correct the position of the left base plate in longitudinal
direction of the vehicle and close the soft top again.
IMPORTANT: Do not repeat the procedure for the right base plate until the left base plate has
been adjusted and the functional check of the soft top function procedure is
completed successfully.
54 37 260 REPLACING REAR-END MODULE HALL SENSOR ON PARTITION WALL
 Open convertible top compartment lid.
Installation:


2007 BMW 335i
Release screw (2).
Feed out Hall sensors.
Installation:
Hall sensor for convertible top cover must be readjusted.
Fig. 394: Identifying Plug Connection And Screw

If there is no signal from the Hall sensors, perform the following adjustments:
Adjusting Hall sensor for roof module:
Loosely tighten screws (1) on holder.
Holder should still be able to be slid in order to center itself.
Stow roof module.
The optimum position of the holders is determined by the retraction of the centering pins into the fastener.

2007 BMW 335i
Fig. 395: Identifying Roof Module Screws

Adjusting Hall sensor for convertible top compartment lid:
Insert screw (2) only loosely.
Pull back Hall sensor (1).
IMPORTANT: Risk of damage! Switch plate must not rest on Hall sensor.
Close convertible top compartment lid carefully.
Fig. 396: Pulling Back Hall Sensor

Adjust Hall sensor (1) in relation to switch plate.
A) 0.4 mm
2007 BMW 335i
Tighten screw (2).
Check function of Hall sensor.
If necessary, reduce gap between Hall sensor and switch plate.
Fig. 397: Identifying Gap Between Hall Sensor And Switch Plate
54 37 290 HARDTOP EMERGENCY OPENING
 13 5 250
 54 0 161
 54 0 163
 54 0 240
 Remove both side trim panel upper sections . See 51 43 012 REMOVING AND
INSTALLING/REPLACING REAR LEFT OR RIGHT UPPER SIDE TRIM SECTION .
 Open all windows
IMPORTANT: Always perform the emergency opening procedure with the aid of an assistant.
The applied force must always be even on the left and right otherwise the
linkage will bend.
Always execute all movements of the roof module with the assistance of a
second person.
Risk of injury by trapping!
Unclip cover cap.

2007 BMW 335i
Attach special tool 54 0 163 together with special tool 13 5 250.
Drive out the square pin.
Fig. 398: Identifying Special Tool (54 0 163 And 13 5 250)

The fasteners open by turning the square pin.
IMPORTANT: Risk of damage! Lower the square pin again after opening the closure.
Turn back the square pin again by a few degrees if necessary.
Turn back square pin a few degrees if necessary.
Fig. 399: Turning Back Square Pin

Open rear lid.
Take out luggage compartment floor trim panel.

2007 BMW 335i
Fig. 400: Removing Luggage Compartment Floor Trim Panel

Release screws (1).

Use Allen key to open shutoff valve on hydraulic unit by one turn.
NOTE: System is now depressurized and can be moved manually.
Close luggage compartment cover.
Close rear lid.

2007 BMW 335i
Fig. 402: Opening Shutoff Valve

Unlocking coupling fastener:
Turn hydraulic cylinder (1) to passenger compartment.
Fit special tool 54 0 161 on piston rod.
Fig. 403: Identifying Special Tool (54 0 161) On Piston Rod

Tilt special tool 54 0 161 upwards.
As a result, the coupling fastener (1) snaps over the dead center position.
Now slide open coupling fastener (1).

2007 BMW 335i
Fig. 404: Sliding Open Coupling Fastener

To join the roof shells, have one person positioned on either side.
It is absolutely essential to grip the front and rear roof shells simultaneously.
Move roof shells carefully and uniformly.
Fig. 405: Moving Roof Shells

Join roof shells uniformly and without tilting.

2007 BMW 335i
Fig. 406: Joining Roof Shells

NOTE: Have special tool 54 0 240 ready.
Open rear-end module manually.
Fig. 407: Opening Rear-End Module

Clip special tool 54 0 240 on to hydraulic cylinder (1) on left and right.
IMPORTANT: The opening in the assembly support must face towards the rear of the vehicle.
2007 BMW 335i
Fig. 408: Identifying Special Tool (54 0 240) To Hydraulic Cylinder

NOTE: Remove any luggage from the luggage compartment (boot).
IMPORTANT: Allow for weight of roof shells.
Only grasp the front roof shell when setting down the roof shells.
Fig. 409: Removing Luggage From Luggage Compartment

Carefully set down the roof shells.
NOTE: Remove special tool 54 0 240.
Close rear-end module.

2007 BMW 335i
Fig. 410: Identifying Roof Shells

IMPORTANT: The convertible top must not be moved any further after emergency opening.
To avoid vibrations, do not subject the vehicle to further movement.
Roof shells which are not locked may cause irreparable damage.
54 37 295 EMERGENCY CLOSING HARDTOP
 13 5 250
 54 0 161
 54 0 162
 54 0 163
 54 0 240
 Remove both side trim panel upper sections . See 51 43 012 REMOVING AND
INSTALLING/REPLACING REAR LEFT OR RIGHT UPPER SIDE TRIM SECTION .
 Open all windows
IMPORTANT: Always perform the emergency closing procedure with the aid of an assistant.
The applied force must always be even on the left and right otherwise the
linkage will bend.
Always execute all movements of the roof module with the assistance of a
second person.
Risk of injury by trapping!
Turn hydraulic cylinder (1) to inside of vehicle.

2007 BMW 335i
Fit special tool 54 0 161 on piston rod.
Fig. 411: Identifying Special Tool (54 0 161) On Piston Rod

Tilt special tool 54 0 161 upwards.
As a result, the coupling fastener (1) snaps over the dead center position.
Now slide open coupling fastener (1).
Fig. 412: Sliding Open Coupling Fastener

Open rear-end module manually.
Clip special tool 54 0 240 on to hydraulic cylinder (1) on left and right.
IMPORTANT: The opening in the assembly support must face towards the rear of the vehicle.
2007 BMW 335i
Fig. 413: Identifying Special Tool (54 0 240) To Hydraulic Cylinder

Mask off air outlet grille with adhesive fabric tape (1).
Carefully press air outlet grille to the side.
Release screws (2) on base plate on left and right.
Installation:
Replace screws.
Right side of vehicle only:
Release screw (3) on Hall sensor.
Fig. 414: Release Screws (2) On Base Plate On Left And Right And Screw (3) On Hall Sensor
Manually open rear lid with key.

2007 BMW 335i
Release screw (1) for locking part on left and right.
Installation:
Replace screws.

NOTE: Remove any luggage from the luggage compartment (boot).

Roof shells cannot yet be lifted out completely!
If necessary, raise roof shells and have third assistant remove items of luggage.
Only grasp the front roof shell when raising the roof shells.

Take out luggage compartment floor trim panel.

2007 BMW 335i
Fig. 417: Removing Luggage Compartment Floor Trim Panel

Release screws (1).

Use Allen key to open shutoff valve on hydraulic unit by one turn.
NOTE: System is depressurized.

2007 BMW 335i

Only grasp the front roof shell when raising the roof shells.

IMPORTANT: Allow for of weight of roof shell!
Lift out roof shells evenly.
NOTE: Plug connection for Hall sensor disconnects as the roof shells are lifted out.
2007 BMW 335i

Remove locking element (1) at rear left and right.
Fig. 422: Identifying Rear Left And Right Locking Element

Remove locking element (1) at front left and right.

2007 BMW 335i
Fig. 423: Identifying Front Left And Right Locking Element

NOTE: Remove special tool 54 0 240.
Close rear end module (1).
Fig. 424: Closing Rear End Module

IMPORTANT: Use suitable aid to prevent placing roof shell on base plates.
Otherwise the extended lock pins of the front roof shell will rest on the middle
roof shell. Risk of damage!
2007 BMW 335i
Fig. 425: Placing Roof Shell On Base Plates

Unfold roof shells evenly.
Fig. 426: Unfolding Roof Shells

Unclip cover cap.
Attach special tool 54 0 163 together with special tool 13 5 250.
Drive out square pin.

2007 BMW 335i
Fig. 427: Identifying Special Tool (54 0 163 And 13 5 250)

The fasteners open by turning the square pin.
Fig. 428: Turning Back Square Pin

Press down on roof shells and convertible top compartment lid on left and right side in marked area.
Use square pin to lock roof shells with fasteners (turn back as far as it will go).
Lower square pin and install cover cap.
Installation:
Square pin is tensioned.
If necessary, use fork wrench to move square pin back and forth while driving in.
2007 BMW 335i
Fig. 429: Locating Roof Shells Area

Fig. 430: Fitting Special Tool (54 0 162) On Connection Joint Of Hydraulic Cylinder
NOTE: Shown here with convertible top open for a better overview.
Fit special tool 54 0 162 on connection joint of hydraulic cylinder.

2007 BMW 335i
Tighten knurled screw (1).
WARNING: Risk of injury! The special tool can slip of if installed incorrectly.
Take appropriate protective measures without fail.
Cover sharp-edged areas.
Wear work clothing with long sleeves and protective gloves.
With the aid of an assistant, press down rear roof shell and convertible top compartment lid and lock coupling
fastener on left and right with special tool 54 0 162.
Pull back coupling fastener over dead center position.
Use Allen key to close shutoff valve on hydraulic unit.
IMPORTANT: The customer must no longer operate the convertible top after it has been
closed with the emergency closing procedure!
To prevent operation, remove fuse 12 for convertible top.
Place removed individual parts in vehicle.
The emergency closing procedure is now completed.
Installation:
Replace screws.
Screw on locking elements loosely.
Locking elements should still be able to be slid in order to center themselves.
Open convertible top.
Open convertible top compartment lid manually with wrench and tighten down screws for rear locking
elements.
Tighten down screws for front locking elements.
Add final details to vehicle.
54 37 300 REMOVING AND INSTALLING/REPLACING REAR WINDOW
IMPORTANT: The instructions on cementing windscreen serve as the basis for this repair
instruction and must be observed without fail. See 51 31... INSTRUCTIONS ON
GLUING WINDSCREEN .

2007 BMW 335i
 00 9 322
 51 0 020
 51 3 010
IMPORTANT: Cover front side panels with protective covers.

When reusing the rear window:
Avoid damaging lines for rear window heating/aerial.
Do not damage cosmetic lip.
 Roof shell, rear

 Remove roofliner for roof shell at rear
NOTE: Removal is performed with Roll Out 2000 .
 Paint coat must not be damaged

 All attachment parts must not be damaged
Roof shell, left side:
Unlock plug connections (2) on aerial amplifier and disconnect.
Fig. 431: Identifying Plug Connection (Left Side)

Roof shell, right side:

2007 BMW 335i
Fig. 432: Identifying Plug Connection (Right Side)

NOTE: To avoid rear window breakage, it is absolutely essential to use wire puller/flat
awl (1).
Slide wire puller/flat awl (1) from Roll Out 2000 from inside between roof shell and rear window through
adhesive bead.
Fig. 433: Identifying Wire Puller/Flat Awl

IMPORTANT: When cutting in area of electric cables (1), insert guard from Roll Out 2000
between electric cables (1), cutting wire and sheet metal.
Components and sheet metal will be damaged if guard is not fitted.
Cut out rear window with Roll Out 2000 .

2007 BMW 335i
Lift out rear window with special tool 51 3 010.
NOTE: Replace rear window if cosmetic lip is damaged.
Fig. 434: Cutting Area Of Electric Cables

Fitting 4 spacer buffers
Only the following spacer buffers may be used:
 Dia. 9.5 mm and 3.8 mm high
IMPORTANT: To avoid rear window breakage and leaks, remove remnants of removed spacer
buffers.
Position new spacer buffers outside adhesive bead.
Adopt position of old spacer buffers on body (outside outer bore holes).
Fig. 435: Identifying Spacer Buffers

2007 BMW 335i
Installation:
Set roof shell down on an absolutely level surface.
Roof shell must not sag or warp.
Place special tool 51 0 020 at top on rear window corners on left and right.
Bring tool exactly into contact with rear window edge and tighten.
NOTE: Position gauge on rear window edge and not on cosmetic lip.
Fig. 436: Placing Special Tool (51 0 020) Top On Rear Window Corners On Left And Right
Overview for rear window cementing (E93)

2007 BMW 335i
Fig. 437: Overview For Rear Window Cementing (E93)

Attach special tool 51 3 010 twice to tool trolley. Moisten suction surfaces and secure rear window from
outside.
If reusing the removed rear window, remove the adhesive residue with a blunt scraper or knife.
Observe treatment of adhesive area in body-cutout and on rear window, see 51 31... INSTRUCTIONS ON
GLUING WINDSCREEN .
Position and width of adhesive bead:
 Overlapping and closed

 Not visible from outside and inside
 The contact point becomes noticeable through an increase in the adhesive volume (approx. 1.5 - 2 x bead
width after crushing).
Position adhesive bead only where the glass ceramic material offers a sufficient overlap and the body
2007 BMW 335i
flange offers sufficient space.
 The adhesive bead is not permitted in the window radii and in the cowl panel area
 Spread adhesive bead with special tool 00 9 322
IMPORTANT: The position of the rear window may not be changed after 5 minutes from
the start of adhesive application as adhesive curing is already too far
advanced.
The window may become detached if this period of time is not maintained.
Window cementing not OK = renewed window cementing necessary.
Position rear window with special tool 51 0 020 on roof shell and press down uniformly.
X: Stop, gauge on roof shell
Y: Centre optically to roof shell
Z: Press down rear window on roof shell until flush
Fig. 438: Identifying Rear Window Cutting Area

Check that rear window (1) is flush with roof outer skin (2).
Z: 0 to -1 mm under-protrusion.
If necessary, press down rear window.
Secure rear window with yellow plastic adhesive tape to roof shell.
NOTE: After pressing down, do not move the rear window any more as this may case
the window to become detached.
Cementing otherwise not OK and renewed cementing necessary.
2007 BMW 335i
Adhesive curing time is adhesive-dependent and must be observed without fail.
Fig. 439: Checking Rear Window Flush With Roof Outer Skin
ROLL BAR, FOLDING

54 62 000 TRIGGERING/RETRACTING ROLLOVER PROTECTION SYSTEM (BMW DIAGNOSIS
SYSTEM)

When the actuators are electrically activated, there must be no persons
present in the vicinity of the rollover protection system.
When rollover protection is mechanically triggered, only one person may
be present underneath the rollover bar.
IMPORTANT: Stow rear end module in convertible top compartment (open).

When the actuators are activated, both rollover bars are simultaneously
triggered.
Triggering rollover protection system:
Refer to diagnostic program "Restraint and rollover protection function / rollover system".
NOTE: The rollover bar can be triggered mechanically if it fails to extend of its own
accord.
Triggering rollover protection system mechanically:
NOTE: Mechanical triggering only possible up to build date/version 03/08.

2007 BMW 335i
 Remove backrest. See SEATS - REPAIR INSTRUCTIONS or SEATS - REPAIR INSTRUCTIONS -

- M3 CONVERTIBLE .
Insert L-shaped Allen key into opening on actuator.
Effect emergency release of rollover bar by pressing.
Fig. 440: Inserting L-Shaped Allen Key Into Opening On Actuator

IMPORTANT: When retracting, make sure rollover bar snaps into place on lower stop.
Slowly relieve load on rollover bar.
Hold locking pawl (1) and press rollover bar (2) down as far as it will go until actuator is locked.
NOTE: Rollover bar must snap audibly into place!
Fig. 441: Pressing Rollover Bar

2007 BMW 335i
54 62 005 REMOVING AND INSTALLING/REPLACING ROLLOVER PROTECTION SYSTEM

When the actuators are electrically activated, there must be no persons
present in the vicinity of the rollover protection system.
When a rollover bar is mechanically triggered, only one person may be
present underneath the rollover bar.
IMPORTANT: When the actuators are activated, both rollover bars are simultaneously
triggered.
Trigger rollover bars.
Installation:

 Remove roof module

 Remove air outlet trim grille . See 51 46 026 REMOVING AND INSTALLING OR REPLACING
FRONT AIR OUTLET TRIM GRILLE .
 Remove both panels for main bearing . See 51 47 207 REMOVING AND
INSTALLING/REPLACING PANEL FOR MAIN BEARING ON LEFT OR RIGHT .
 Remove panel for passenger compartment partition . See 51 47 143 REMOVING AND
INSTALLING/REPLACING PANEL FOR PASSENGER COMPARTMENT PARTITION .
 Remove control unit . See 65 77 770 REMOVING AND INSTALLING (REPLACING)
ROLLOVER CONTROLLER .
 Remove inertia reel mechanism and sash guide on left and right. See 72 11 092 REMOVING AND
INSTALLING/REPLACING REAR LEFT OR RIGHT SEAT BELTS .
Unlock plug connection (1) on left and right and disconnect.

2007 BMW 335i

Release screws (1).
Remove rollover protection system strut.

Release screws (1).
Tightening torque: see 1AZ in 54 62 ROLLOVER PROTECTION SYSTEM, FOLDING .
Remove screw fastening plate.

2007 BMW 335i
Fig. 444: Identifying Screw Fastening Plate

Release screws (1).
Tightening torque: see 3AZ in 54 62 ROLLOVER PROTECTION SYSTEM, FOLDING .
Lift out rollover protection system.
Installation:
Carry out function check.

Replacement only:
Release screws (1) on all holders for middle trim grille.

2007 BMW 335i
Remove holders for trim grille.
Release screws (2) on holders for rear trim grille.
Remove holders for trim grille.
Modify all holders for control units.
Fig. 446: Identifying Holder Screws

Release screws (1).
Modify striker with holders.

54 62 010 REMOVING AND INSTALLING OR REPLACING TRIM COVER ON LEFT OR RIGHT

2007 BMW 335i
ROLLBAR
 Remove both rear headrests . See SEATS - REPAIR INSTRUCTIONS or SEATS - REPAIR
INSTRUCTIONS -- M3 CONVERTIBLE .
Undo left/right screws (1) and detach left/right trim panel (2) by lifting upwards.
Tightening torque: see 4AZ in 51 46 PANEL, REAR PARCEL SHELF, ROLLER SUN BLIND .
Fig. 448: Identifying Trim Panel Screws

2007 BMW 335i
ENGINE Cooling System - Repair
ENGINE
Cooling System - Repair
COOLANT, CHECKING COOLING SYSTEM

17 00 009 CHECKING COOLING SYSTEM FOR WATER LEAKS
 00 2 030
 17 0 101
 17 0 113
 17 0 114
WARNING: Risk of scalding!

Only perform this work after engine has cooled down.
 Wear safety goggles

 Observe national/country-specific regulations
IMPORTANT: Risk of slipping due to coolant on the floor.

Risk of injury!
Catch and dispose of drained coolant in drip tray (1) and if necessary special tool 00 2 030 (universal hydraulic
lifting equipment).
Recycling:

2007 BMW 335i
Fig. 1: Identifying Drip Tray And Special Tool 00 2 030 (Universal Hydraulic Lifting Equipment)
Checking pressure drop in cooling system
Open cap on coolant expansion tank. Fit special tool 17 0 101 / 17 0 113 .
Build up gauge pressure, wait approx. 2 minutes.
Cooling system is impervious to leaks if pressure drop is max. 0.1 bar.
Fig. 2: Identifying Special Tool 17 0 101 / 17 0 113

Checking pressure relief valve in cap

2007 BMW 335i
NOTE: While the vehicle is driven at high outside temperatures, the design may cause
the pressure relief valve in the cap to open slightly and air together with
dissolved coolant to escape. This coolant vapour condenses on the surface of
the expansion tank and leaves traces when the vehicle has cooled down. These
traces do not indicate whether the cap is defective or not. When the vehicle has
been parked up for an extended period of time, the residual escaping coolant
can cause the pressure relief valve in the sealing cap to stick; therefore check
the cap again 2 to 3 times.
Replace the cap only after you have checked three times and there is an incorrect opening pressure.
Checking pressure relief valve in cap
Screw cap (1) onto special tool 17 0 114 .
Build up pressure with special tool (hand pump) 17 0 101 ; observe pressure gauge to ascertain when opening
pressure is achieved.
Compare OPENING PRESSURE OF PRESSURE RELIEF VALVE .
Fig. 3: Checking Pressure Relief Valve In Cap

17 00 515 CHECKING FUNCTION OF RADIATOR AND HEATING SYSTEM
 13 3 010

2007 BMW 335i
Only carry out work on cooling system after engine has cooled down.
 Switch off ignition.

 Remove air duct.
 Remove fan cowl with electronic fan.
Check production date.
Fig. 4: Locating Production Date

Clamp off low-temperature feed lines with special tool 13 3 010.
Function test:
Observe diagnosis instructions.

2007 BMW 335i
Fig. 5: Identifying Low-Temperature Feed Lines And Special Tool 13 3 010

Check function of radiator.
Clamp off low-temperature feed line (1) at coolant pump outlet or radiator inlet with special tool 13 3 010 (see
arrows).
Fig. 6: Locating Low-Temperature Feed Line At Coolant Pump Outlet Or Radiator Inlet
Automatic transmission only
Check function of heat exchanger.

2007 BMW 335i
Clamp off low-temperature feed line (1) at coolant pump outlet with special tool 13 3 010 (see arrow).
Clamp off low-temperature feed line (2) at oil-coolant heat exchanger with special tool 13 3 010 (see arrow).
Fig. 7: Locating Low-Temperature Feed Line At Coolant Pump Outlet And Oil-Coolant Heat Exchanger
Check heating and cooling circuits in accordance with diagnosis instruction.
17 00 008 DRAINING AND ADDING COOLANT (N54, N54T)
 00 2 030

Only carry out repair work on the cooling system after the engine has
cooled down!
Important!
Lifetime coolant filling
Never reuse used coolant!
When replacing and removing components which rely on the corrosion protection effect of the coolant, it is
essential to change the coolant. The cooling system must therefore be drained and refilled.
In the case of other removal work involving the draining of part quantities of coolant, replace these quantities
which have been drained with new coolant.
2007 BMW 335i
Installation note:
Use only recommended coolant. Observe mixture ratio. See COOLING SYSTEM - OPERATING FLUIDS .
 Wear safety goggles

 Observe national/country-specific regulations
IMPORTANT: For dirt contamination of the cooling system (e.g. by engine oil), the cooling
system must be rinsed with water until all dirt contamination is removed!
IMPORTANT: Risk of skidding due to coolant on the floor.
Danger of injury!
Catch and dispose of drained coolant in drip tray (1) and if necessary special tool 00 2 030 (universal hydraulic
lifting equipment).
Recycling
 Follow notes for CARRYING OUT REPAIR WORK ON THE COOLING SYSTEM.
2007 BMW 335i
 Remove CHARGE AIR COOLER.
Draining coolant
Open sealing cap (1) on coolant expansion tank (2).
Installation note:
Close sealing cap (1) until the arrow marks line up.
Fig. 9: Closing Sealing Cap Until Arrow Marks Line Up

Open coolant drain plug (1).
Drain, catch and dispose of coolant.
Installation note:
 Replace sealing ring.

 Tightening torque 17 11 2AZ .
2007 BMW 335i
Fig. 10: Identifying Coolant Drain Plug

Unfasten and detach coolant hose (1) from thermostat housing.
Drain, catch and dispose of coolant.
Fig. 11: Identifying Coolant Hose

NOTE: Adding coolant:

Use only recommended coolant.
Observe mixture ratio. See COOLING SYSTEM - OPERATING FLUIDS .
Observe capacities. See COOLING SYSTEM - TECHNICAL DATA (N54) .
2007 BMW 335i
Observe bleeding instructions without fail.

FILL AND BLEED COOLING SYSTEM.
Visual inspection of cooling system for tightness.
17 00... INSTRUCTIONS FOR REPAIR WORK ON COOLING SYSTEM
WARNING: Risk of scalding. Only carry out repair work on the cooling system after
the engine has cooled down.
IMPORTANT: Wear protective gloves and safety goggles.
Important!
Never reuse used coolant.
When replacing and removing components which rely on the corrosion protection effect of the coolant, it is
essential to change the coolant. The cooling system must therefore be drained and refilled.
In the case of other removal work involving the draining of part quantities of coolant, replace these quantities
which have been drained with new coolant.
IMPORTANT: Open cooling system only when it has cooled down.

Opening the cooling system while hot can result in air entering the system.
This can cause overheating with permanent damage to the engine.
IMPORTANT: You must protect the alternator against dirt contamination before carrying out
any repair work on the cooling circuit.
Cover alternator with suitable materials.
Failure to comply with this procedure may result in an alternator malfunction.
IMPORTANT: Do not fill coolant expansion tank over MAX level as overfilling will cause the
coolant to overflow. This may give rise to traces of coolant on the expansion
tank or in the engine compartment and wrongly suggest possible leaks.
Recycling
NOTE: To disconnect coolant hoses, use commercially available disconnect tools such
as HAZET brand tools (see table).
2007 BMW 335i
Fig. 12: Identifying Disconnect Tools

HAZET no.: Designation

4590-1 Disconnect-pliers, length (mm): 150
4590 / 2 Disconnect-plier set
4590 / 3 Disconnect-plier set
NOTE: Tightening torque for hose clamps
WAF 5 1.0 - 1.5 Nm

WAF 6 2.5 - 3.5 Nm
2007 BMW 335i
Fig. 13: Locating Hose Clamp Screw

Instructions for dismantling/assembly of coolant hose quick-release couplings
Dismantling of quick-release coupling
Pull out lock (1) and (2). Pull off hose.
Fig. 14: Dismantling Of Quick-Release Coupling

Installation note:
Check O-rings (1).

2007 BMW 335i
Do not coat O-rings (1) with lubricant.
Fig. 15: Checking O-Rings

Assembly of quick-release coupling
Press in lock (1) before installing quick-release coupling.
Push on hose.
Quick-release couplings must clearly snap audibly into place.
Fig. 16: Assembling Of Quick-Release Coupling

2007 BMW 335i
17 00... NOTES ON RETROFITTING A TRAILER TOWING DEVICE
Starting with delivery of the E90, in certain vehicle types, the size of the electric cooler fan will be linked to the
optional extra trailer tow hitch or trailer provision.
A larger fan may therefore be required for retrofits. Please refer to the BMW ETK (Electronic Parts Catalogue)
for exact allocation.
The larger fan is necessary to ensure mountain driving with a full trailer load in accordance with BMW-internal
specifications. Otherwise the engine electronics will detect possible overheating of the cooling system and
activate protective functions.
For the customer, this involves impaired A/C output, automatic transmission and engine power. These will be
continuously reduced, which in the end may result in the vehicle coming to a standstill in the mountain area.


the information "switch closed" is output. The automatic engine start-stop
function is active.

2007 BMW 335i
Fig. 17: Identifying MSA Button

 Workshop mode
A = 10 mm
B = 7 mm
2007 BMW 335i
Fig. 18: Identifying Engine Hood/Bonnet Contact (Basic Setting And Workshop Mode)
17 00 039 VENTING AND FILLING COOLING SYSTEM WITH VACUUM FILLING UNIT
 00 2 030
 17 0 100
Type Engine Adapter Y from 17 0 100

E60 / E61 / E63 / E64 All 17 0 113
E65/E66 M54 / N52 / N62 / N62T / N73 17 0 105
E65/E66 M57S / M57T / M67 / M67T 17 0 113
E70 / E71 / E72 All 17 0 113
E81/ E82/ E84/ E87/ E88/ E89 All 17 0 113
E83 M54/ N46/ N52K 17 0 105
E83 M47S / M57S / M57T / M57Y / N47 17 0 113
E85 / E86 All 17 0 105
E90 / E91 / E92 / E93 All 17 0 113
R50 / R52 W10 17 0 107 and 17 0 102
R50 W17 17 0 109
R52 / R53 W11 17 0 109
R55 / R56 / R57 / R58 / R60 / R61 All 17 0 109
F25 All 17 0 113
F20 / F21 / F30 / F31 N47 D20 K/U/O/T 1 17 0 113
F20 / F21 / F30 / F31 / F35 N13 / N20 17 0 113
F30 / F31 / F35 N55 / N55 hybrid car 17 0 113
F30 / F31 N57 D30 O/T 1 17 0 113
IMPORTANT: Never reuse used coolant!

When replacing and removing components which rely on the corrosion
protection effect of the coolant, it is essential to change the coolant. The
cooling system must therefore be drained and refilled.
In the case of other removal work involving the draining of part quantities of
coolant, replace these quantities which have been drained with new coolant.
IMPORTANT: You must protect the alternator against contamination by coolant when
carrying out repair work on the cooling circuit.

2007 BMW 335i
Note on ordering:
 Workshop equipment
 Workshop equipment catalogue
 Filler unit no. 81 39 2 152 473
 Collecting vessel no. 81 49 2 152 347
 Adapter: 17 0 100
IMPORTANT: Risk of slipping due to coolant on the floor.

Danger of injury!
Catch and dispose of emerging coolant in drip tray (1) and if necessary special tool 00 2 030 (universal
hydraulic lifting equipment).
Recycling
IMPORTANT: Check all the coolant hoses before filling the cooling system with the vacuum
filling unit.
If necessary, replace damaged and porous coolant hoses.
2007 BMW 335i
Fig. 20: Filling Cooling System With Vacuum Filling Unit

 1) Filling unit with vacuum meter and shutoff valves

 2) Filler hose
 3) Coolant container
 4) Venturi nozzle
 5) Compressed air connection (max. 6 bar)
 6) Outgoing-air hose (lead outgoing-air hose into a collecting container)
Preconditions
 Cooling system expansion tank must be empty.

 There must be sufficiently premixed coolant in the filling unit container, 1 - 2 liters more than the vehicle
filling capacity.
 Use only recommended coolant. Observe mixture ratio.
 See COOLING SYSTEM - OPERATING FLUIDS .
 Observe capacities. See COOLING SYSTEM - TECHNICAL DATA (N54) .
 Position the filling unit container at the same height as the coolant expansion tank.
 Compressed-air connection with 6 bar pressure present.
2007 BMW 335i
 Set vehicle heater to maximum temperature.
Select adapter (Y) according to table and connect to coolant expansion tank.
Connect filler unit to adapter connection (X).
Fig. 21: Connecting Filler Unit To Adapter Connection (X)

Shutoff valves (A) and (B) of the filling unit (1) must be closed.
(X) Expansion tank connection
Fig. 22: Identifying Shutoff Valves (A) And (B) Of Filling Unit Must Be Closed
2007 BMW 335i
Connect venturi nozzle (1) to filling unit (2).
Fig. 23: Connecting Venturi Nozzle To Filling Unit

Connect compressed air (1).
Fig. 24: Connecting Compressed Air

2007 BMW 335i
Open shutoff valve (B).
The venturi nozzle produces a flow noise.

Then open shutoff valve (A) until the filling hose (1) is free of bubbles.
Close shutoff valve (A) again. The filling hose (1) is vented in this way.
Fig. 26: Opening Shutoff Valve Until Filling Hose Is Free Of Bubbles
Shutoff valve (B) remains open. Generate vacuum in coolant system for approx. 2 minutes. The end vacuum is
2007 BMW 335i
reached at a vacuum of -0.7 to -0.95 bar. Green scale on the vacuum meter.
NOTE: The coolant hoses contract during vacuum build-up.
Then close shutoff valve (B) again.
Fig. 27: Generating Vacuum In Coolant System For Approx. 2 Minutes

Both shutoff valves (A) and (B) must be closed. Then seal Venturi nozzle (1).
Fig. 28: Sealing Venturi Nozzle

2007 BMW 335i
The cooling system must hold the vacuum for 30 s. If the needle in the vacuum meter falls, this indicates a leak
in the cooling system.
If the vacuum remains constant, proceed with filling.
In event of leaks, check cooling system for leaks.
Fig. 29: Holding Cooling System Vacuum For 30 Seconds

IMPORTANT: There must be sufficiently premixed coolant in the filling unit container: 1-2
liters more than the vehicle filling capacity.
Position the filling unit container at the same height as the coolant expansion tank.
Shut-off valve (B) remains closed during the filling process.
To fill the cooling system, open shutoff valve (A) to filling unit container.
2007 BMW 335i
Fig. 30: Shut-Off Valve Remains Closed During Filling Process

Coolant is now added.
The filling procedure is finished when the needle in the vacuum meter is at 0 bar or no longer falls.
If necessary, reduce remaining vacuum. Open shutoff valve (B) to do so.
Fig. 31: Filling Coolant

Remove filling unit with adapter from expansion tank.
Adjust coolant level to maximum.

2007 BMW 335i
Close coolant expansion tank.
Fig. 32: Adjusting Coolant Level To Maximum

After the cooling system has been filled with the vacuum filling unit, another bleeding procedure must be performed for
the following vehicles
 E84 N20
 F25 N52T, N55
 F25 N20
 E70, E71 N63, S63
 E70, E71 N57 D30 S 1
 E72 N63
 F20, F21, F30 N13
 F20, F21, F30, F31, F35 N20, N26
 F20, F21, F30, F31, F35 N55
 F30 N55 Hybrid
After the cooling system has been filled with the vacuum filling unit, another bleeding procedure must be performed for
vehicles with an electric coolant pump
NOTE: Do not open the coolant expansion tank cap during the bleeding procedure.
Switch on the low-beam headlights to perform the bleeding procedure. If the
low-beam headlights are not switched on, the ignition (Terminal 15) will switch
off automatically after a certain period of time and interrupt the bleeding
procedure.
1. Connect battery charger.

2007 BMW 335i
2. Switch the ignition on.

3. Switch on low-beam headlight.
4. Set heating to maximum temperature. Take back blower to smallest stage.
5. FES (driving experience switch) must not be in ECO PRO!
6. Press accelerator pedal for 10 seconds to floor. Engine must not be started.
7. The venting procedure is started when the accelerator pedal is pressed and takes approx. 12 minutes.
(Electric coolant pump was activated and shuts down automatically after approx. 12 min).
8. Then adjust fluid level in the coolant expansion tank to maximum.
9. Check cooling system for leaks.
10. If the ventilation has to be performed again, deactivate DME completely (remove ignition key for approx.
3 minutes). Then repeat from point 3.
Check function of cooling system.
Check cooling system for tightness.
17 00 039 VENTING COOLING SYSTEM AND CHECKING FOR WATERTIGHTNESS (N54)

Open sealing cap only after engine has cooled down.
IMPORTANT: Electric coolant pump!

FOLLOW NOTES FOR CARRYING OUT REPAIR WORK ON THE COOLING
SYSTEM.
IMPORTANT: Lifetime coolant filling:

Never reuse used coolant!
When replacing and removing components which rely on the corrosion
protection effect of the coolant, it is essential to change the coolant. The
cooling system must therefore be drained and refilled.
In the case of other removal work involving the draining of part quantities of
coolant, replace these quantities which have been drained with new coolant.
Only when refilling!
Use only recommended coolant. Observe mixture ratio. See COOLING SYSTEM - OPERATING FLUIDS .
Perform filling operation slowly.
Adjust coolant level to MAX.

2007 BMW 335i
Fig. 33: Adjusting Coolant Level To MAX

Installation note:
Close the sealing cap (1) until the arrows line up.

IMPORTANT: The following bleeding procedure is necessary e.g. when a part is replaced in
the cooling system or when the cooling system is refilled.
2007 BMW 335i
Vehicles with independent heating only
Open bleeder screw (1).
Slowly fill coolant expansion tank with recommended coolant. See COOLING SYSTEM - OPERATING
FLUIDS .
Close bleeder screw (1) after coolant emerges.
Installation note:
Have a cleaning cloth ready and mop up emerging coolant.
Fig. 35: Identifying Bleeder Screw

Adding coolant
NOTE: Open bleeder screw (1).
Fill coolant expansion tank up to lower edge of filler neck with recommended coolant. Observe mixture ratio.
See COOLING SYSTEM - OPERATING FLUIDS .
Close bleeder screw (1).
Close cap on expansion tank.
Installation note:
Have a cleaning cloth ready and mop up emerging coolant.

2007 BMW 335i
Fig. 36: Identifying Bleeder Screw

Only when venting!
NOTE: Do not open the coolant expansion tank cap during the bleeding procedure.
1. Connect battery charger.

2. Switch the ignition on.
3. Set heater to maximum temperature and turn blower down to lowest speed.
4. Press accelerator pedal for 10 seconds to floor. Engine must not be started.
5. The bleeding procedure was started by pressing the accelerator pedal and takes approx. 12 min. (the
electrical coolant pump was activated and switches off automatically after approx. 12 min).
6. Then top up fill level in coolant expansion tank with 100 ml above MAX (see illustration).
7. CHECK COOLING SYSTEM FOR WATERTIGHTNESS .
8. If venting has to be carried out again (e.g. if cooling system is leaking), allow DME to fall completely
(leave ignition key removed for approx. 3 min), then repeat from Point 3.
Only when venting!
Perform filling operation slowly.
Fill coolant expansion tank with 100 ml above MAX.
100 ml corresponds to A=6 mm.

2007 BMW 335i
Fig. 37: Filling Coolant Expansion Tank With 100 ml Above MAX
Installation note:
Close the sealing cap (1) until the arrows line up.

RADIATOR, EXPANSION TANK, PIPES

2007 BMW 335i
64 53... INSTRUCTIONS FOR REPLACEMENT OF AIR CONDITIONING CAPACITORS AND

RADIATOR/COOLERS
IMPORTANT: Even when they are correctly installed or due to normal driving, coolers (oil
cooler, radiator, charge air cooler) or air conditioning capacitors may show
slight impressions or deformations on their discs (picture).
This is not damage.
Radiators, cooler or capacitors are not to be replaced in this case.
NOTE: The deformations shown in Fig. 39 can be bent back with a standard fin comb..
Damage to lines carrying media or on the flat pipe require replacement of the radiator/or air conditioning
condenser (picture 2-6).
Fig. 39: Identifying Damaged Lines Of Radiator/Or Air Conditioning Condenser

ENGINE RADIATOR WITH ATTACHMENT

17 11 370 REMOVE AND INSTALL OR REPLACE THE COOLING LOOP FOR HYDRAULIC
STEERING (N54, N54T, N52, N52K, N51, N53, S65)
2007 BMW 335i

Only perform this repair work after engine has cooled down.
IMPORTANT: When carrying out repair work on the oil and cooling circuit, protect the
alternator against dirt contamination.
 After completing this repair work, check the oil level in the oil reservoir of the hydraulic steering.
 Remove RADIATOR.
Press lines (1) in direction of cooling loop (2), pull back locking ring towards rear. Keep locking ring pressed
and detach lines (1) from cooling loop (2).
IMPORTANT: Catch and dispose of emerging oil.
Fig. 40: Identifying Lines And Cooling Loop

Unlock seal (1) in direction of arrow and remove.
Release screw.
NOTE: Lines of A/C system remain connected to capacitor.

2007 BMW 335i
Fig. 41: Identifying Seal Unlock Direction

Press lock (1) upwards.
Carefully tilt capacitor (2) in direction of engine, taking care not to damage the capacitor or lines in the process.
Fig. 42: Identifying Capacitor Tilting Direction

Press lock (1).
Unclip cooling loop (2) from holder (3) and remove.

2007 BMW 335i
Fig. 43: Identifying Lock, Cooling Loop And Holder

17 11 035 REMOVE AND INSTALL OR REPLACE THE FAN COWL WITH ELECTRIC FAN(N53,
N54, N54T, N55)
 Read out the fault memory of the DME control unit.

 Switch off ignition.
 Remove intake port.
 Only automatic or twin-clutch gearbox: Remove front underbody protection.
Only automatic or twin-clutch gearbox
Release screw.
Detach cooler (1) for automatic transmission from fan cowl (2).
2007 BMW 335i
Fig. 44: Identifying Screw, Cooler And Fan Cowl

Unlock connector (1) and remove.
Unclip line (2) from fan cowl.
Cut open cable strap (3).
Release screw.
Fig. 45: Identifying Connector, Line And Open Cable Strap

Release charge air duct (1) from rubber mount (2) on fan cowl.
2007 BMW 335i
Fig. 46: Identifying Charge Air Duct And Rubber Mount

Unlock catch in direction of arrow.
Remove fan cowl towards top.
Fig. 47: Identifying Catch Unlock Direction

Installation note:
Make sure fan cowl (1) and holder (2) are in correct installation position.
2007 BMW 335i
Fig. 48: Identifying Fan Cowl And Holder

NOTE: Check stored fault messages.

Delete fault memory.
17 11 046 REMOVING AND INSTALLING / REPLACING MODULE CARRIER
 Remove COOLANT COOLER

 If necessary, slacken power steering cooling coil; refer to REMOVING POWER STEERING
COOLING COIL
 If necessary, slacken A/C condenser and secure against damage and against falling down.
Release damping pieces.

2007 BMW 335i
Fig. 49: Locating Damping Pieces

Press lock (1) and remove holder (2) downwards.
Illustration shows the left holder: The same procedure applies to the opposite side.
Installation:
Rubber mounts fall out easily, ensure correct installation position.
Fig. 50: Identifying Lock And Holder

Remove module carrier (1) individually towards bottom.

2007 BMW 335i
Fig. 51: Identifying Module Carrier

When replacing module carrier:
Convert power steering COOLING LOOP.
17 11 000 REMOVING AND INSTALLING RADIATOR (N53, N54, N54T)

IMPORTANT: Wear safety goggles and protective gloves.
 Follow instructions for REPAIR WORK ON THE COOLING SYSTEM.

 Remove FAN COWL.
 Drain COOLANT.
 Unlock coolant hoses and detach.
Only on N54, N54T:
Release the clamp and detach and remove the charge air duct (1).
Tightening torque 13 71 6AZ.

2007 BMW 335i
Fig. 52: Identifying Clamp And Charge Air Duct

Automatic only:
Release bolt and detach hose (1).
Fig. 53: Identifying Bolt And Hose

Automatic only:
Release bolt (1) and detach hose (2).

2007 BMW 335i
Fig. 54: Identifying Bolt And Hose

Release screws.
Carefully feed out radiator (1) towards top and remove.
Fig. 55: Removing Radiator

17 11 063 REMOVING AND INSTALLING/REPLACING BOTH RADIATOR BRACKETS (N54,

N54T, N52, N52K, N51, N53)
2007 BMW 335i
 Remove condensor. HEATING AND AIR CONDITIONING - REPAIR -- E90 HEATING AND AIR
CONDITIONING - REPAIR - E92/E93 HEATING AND AIR CONDITIONING - REPAIR -
E90/E91
 REMOVE cooling loop for hydraulic steering
NOTE: Texts refer to and illustrations show the left side. The procedure is identical for
the right intake duct.
Release screw.
Fig. 56: Locating Screw

Remove holder (1).

2007 BMW 335i

17 11 100 REMOVING AND INSTALLING/REPLACING COOLANT EXPANSION TANK (N53, N54,

N54T)
 Drain COOLANT from radiator.
N54: Unclip vacuum hoses.
Undo screws (2).
Lift expansion tank (3) slightly until connector on the bottom of the coolant level switch and coolant hose is
accessible.
Release and unplug connector on the bottom from coolant level switch and coolant hose.
2007 BMW 335i
Fig. 58: Identifying Coolant Hose, Screws And Expansion Tank

Remove coolant expansion tank (3).
Installation note:
Insert retaining pin in rubber grommet.
VENT COOLING SYSTEM and check for leaks.
17 11 150 REMOVING AND INSTALLING/REPLACING ENGINE OIL COOLER (N54, N54T, N55)
 Remove front right wheel arch cover (front section). See 51 71 038 REMOVING AND
INSTALLING/REPLACING FRONT LEFT OR RIGHT WHEEL ARCH COVER (FRONT
SECTION) (E90/E91, 2006-08) , 5171038 REMOVING AND INSTALLING/REPLACING FRONT
LEFT OR RIGHT WHEEL ARCH COVER (FRONT SECTION) (E90, 2009-10) or 51 71 038
REMOVING AND INSTALLING/REPLACING FRONT LEFT OR RIGHT WHEEL ARCH
COVER (FRONT SECTION) (E92/E93, 2007-10) .

IMPORTANT: Wear safety goggles and protective gloves.
Recycling
Engine oil escapes when the engine oil pipes are released. Catch and dispose of emerging engine oil.
2007 BMW 335i
Release screw.
Detach engine oil pipes (1) from engine oil cooler flange.
Catch and dispose of emerging oil.
Fig. 59: Identifying Engine Oil Pipes

Installation note:

2007 BMW 335i
Fig. 60: Locating Sealing Rings

Release screws.
Unscrew nuts (1).
Release screw (2).
Feed out engine oil cooler (3) and remove.

2007 BMW 335i
Fig. 61: Identifying Nuts, Screw And Engine Oil Cooler

NOTE: After completing the repair work, check engine oil level and top up engine oil if
necessary.
17 11 190 REMOVING AND INSTALLING/REPLACING ENGINE OIL PIPE FOR OIL COOLER
(N54, N54T, N55)

IMPORTANT: Wear protective gloves and safety goggles.
Recycling
Engine oil escapes when the engine oil pipes are released.
Catch and dispose of emerging engine oil.
Remove FAN COWL.
Release screw.
Detach engine oil pipe (1) from oil filter control housing.

2007 BMW 335i
Fig. 62: Identifying Engine Oil Pipe At Oil Filter Control Housing
Release screw.
Disconnect engine oil pipe (1) from engine oil cooler flange and remove.
IMPORTANT: When tightening down the bolt, use suitable means/equipment to prevent the
flange from twisting.
Twisting of the flange can lead to contact with the front panel! This in turn
results in vibration noises and corrosion damage.
2007 BMW 335i
Fig. 63: Identifying Engine Oil Pipe At Engine Oil Cooler Flange
Installation note:
Replace all sealing rings of engine oil pipes!
Fig. 64: Locating Sealing Rings Of Engine Oil Pipes

NOTE: After completing the repair work check oil level; top up if necessary.
OIL COOLER
2007 BMW 335i
17 21 500 FLUSHING TRANSMISSION OIL COOLER WITH LINES (AUTOMATIC

TRANSMISSION)
 17 2 018
 17 2 019
NOTE: Carry out the work steps listed when:

Installing a new or replacement transmission.
Flushing can only be carried out with the automatic transmission removed.
Procedure
Automatic transmission removed.
Connect appropriate adapters (see description below) to oil lines exiting from automatic transmission.
Connect connecting line 17 2 019 from the oil collection unit with the quick-release coupling.
Connect drain line 17 2 018 using quick-release coupling.
Hold and direct open end of drain line into a suitable drip tray.
Using oil collection unit, flush approx. 1 litre of transmission fluid (refer to AUTOMATIC TRANSMISSION
- OPERATING FLUIDS ) through oil lines and transmission oil cooler.
Reposition quick-release couplings.
Flush oil lines/transmission oil cooler in opposite direction with approx. 1 litre of transmission fluid (refer to
AUTOMATIC TRANSMISSION - OPERATING FLUIDS ).
Disconnect quick-release couplings.
Remove adapter.
NOTE: Dispose of flushing oil correctly.

Do not reuse under any circumstances.
Arrangement, flushing apparatus for transmission A5S 310Z, A5S 560Z, A5S 360R/390R, A4S 200R, A5S 325Z
2007 BMW 335i
Fig. 65: Identifying Arrangement Of Flushing Apparatus For Transmission A5S 310Z, A5S 560Z, A5S
360R/390R, A4S 200R, A5S 325Z
1. Transmission oil cooler with lines

2. Oil collection unit
3. Oil drip tray
17 2 011 Adapter for connecting transmission-side oil cooler lines (1)
17 2 015 Connection for oil collection unit (2), manufacturer: Deutsche Tecalemit or
17 2 016 Connection for oil collection unit (2), manufacturer: Horn
17 2 017 Quick-release coupling (2 pieces)
17 2 018 Hose to oil drip tray (3)
17 2 019 Hose to oil collection unit (2)
17 2 021 Mounting plate for adapter 17 2 011 for transmissions A5S 325Z, GA6HP26Z
Arrangement of flushing apparatus for transmission A4S 310R

2007 BMW 335i
Fig. 66: Identifying Arrangement Of Flushing Apparatus For Transmission A4S 310R

3. Oil drip tray
17 2 012 Adapters (2 x) for connecting transmission-side oil cooler lines (1)
Arrangement of flushing apparatus for transmission A4S 300J

2007 BMW 335i
Fig. 67: Identifying Arrangement Of Flushing Apparatus For Transmission A4S 300J

3. Oil drip tray
17 2 014 Banjo bolt for connecting transmission-side oil cooler lines (1)
Arrangement of flushing apparatus for transmission A5S 440Z

2007 BMW 335i
Fig. 68: Identifying Arrangement Of Flushing Apparatus For Transmission A5S 440Z

3. Oil drip tray
17 2 013 Banjo bolt for connecting transmission-side oil cooler lines (1)
17 21 500 FLUSHING TRANSMISSION OIL COOLER WITH LINES (AUTOMATIC

TRANSMISSION) (GA6HP19Z, GAHP26Z, GA6HP32Z)
2007 BMW 335i
 17 2 018
 17 2 019
NOTE: Carry out the work steps listed when:

Installing a new or replacement transmission.
Procedure
Automatic transmission removed.
Connect appropriate adapters (see description below) to oil lines exiting from automatic transmission.
Connect connecting line 17 2 019 from the oil collection unit with the quick-release coupling.
Connect drain line 17 2 018 using quick-release coupling.
Hold and direct open end of drain line into a suitable drip tray.
Using oil collection unit, flush approx. 1 litre of transmission fluid (refer AUTOMATIC TRANSMISSION -
OPERATING FLUIDS ) through oil lines and transmission oil cooler.
Reposition quick-release couplings.
Flush oil lines/transmission oil cooler in opposite direction with approx. 1 litre of transmission fluid (refer to
AUTOMATIC TRANSMISSION - OPERATING FLUIDS ).
Disconnect quick-release couplings.
Remove adapter.
NOTE: Dispose of flushing oil correctly.

Do not reuse under any circumstances.
Press hydraulic lines (1) into adapters (2).
Slide clamping bar (3) into guides and secure with screw (4).
2007 BMW 335i
Fig. 69: Identifying Hydraulic Lines, Adapters, Clamping Bar And Screw
Arrangement of flushing apparatus for transmissions GA6HP19Z, GA6HP26Z, GA6HP32Z
Fig. 70: Identifying Arrangement Of Flushing Apparatus For Transmissions GA6HP19Z, GA6HP26Z,
GA6HP32Z
2007 BMW 335i
1. Transmission-oil cooler with lines

3. Oil drip tray
4. Adapter with clamping bar
17 2 060 Adapter with clamping bar for aluminium lines and steel lines with aluminium connection (line
diameter 12 mm) GA6HP19Z
17 2 070 Adapter with clamping bar (line diameter 15 mm) GA6HP26Z, GA6HP32Z, TCT for N54
engine
17 2 080 Adapter with clamping bar for fuel lines GA6HP26Z
17 22 010 REMOVING AND INSTALLING/REPLACING GEARBOX OIL COOLER FOR

AUTOMATIC TRANSMISSION (N54, N54T)
IMPORTANT: Risk of scalding!

 Drain COOLANT .
 Remove underbody protection
Recycling
Catch and dispose of drained coolant in a suitable container.
Transmission oil emerges when fluid lines are detached from transmission oil cooler.
Catch and dispose of escaping transmission oil in a suitable container.

2007 BMW 335i
Release and disconnect coolant hoses (1).
Unlock transmission oil lines (2) and detach.
Release screw (3).
Remove transmission oil cooler (4).
Fig. 71: Identifying Coolant Hoses, Transmission Oil Lines, Screw And Transmission Oil Cooler
NOTE: Assemble engine.

Check oil level in automatic transmission. If necessary, top up automatic
transmission oil.
CHARGE AIR COOLER WITH MOUNT

17 51 000 REMOVING AND INSTALLING/REPLACING CHARGE AIR COOLER (N54, N54T, N55)
 11 8 670
 Remove front underbody protection.

 Unfasten and detach charge air duct on left and right of charge air cooler.
 Only E84 with pedestrian protection:
2007 BMW 335i
Remove pedestrian protection.
IMPORTANT: Coat sealing rings of snap fasteners with lubricant.

Pressure pipes cannot be fitted without lubricant.
Only, when cover (1) is installed:
Release lock on cover (1) in direction of arrow.
Fig. 72: Identifying Cover Lock Release Direction

Only, when cover (1) is installed:
Release cover (1) in direction of arrow and remove.

2007 BMW 335i
Fig. 73: Identifying Cover Release Direction

Release screws and remove charge air cooler (1).
Fig. 74: Identifying Screws And Charge Air Cooler

Installation note:
Make sure charge air cooler (1) and cooler bracket (2) are in correct installation position.
2007 BMW 335i
Fig. 75: Identifying Charge Air Cooler And Cooler Bracket

Installation note:
Make sure charge air cooler (1) and cooler bracket (2) are in correct installation position.
Fig. 76: Identifying Charge Air Cooler And Cooler Bracket

Installation note:
CAUTION: Risk of damage to sealing rings!

2007 BMW 335i
Special tool 11 8 670 is essential!
 Coat sealing rings with antiseize agent.

 Attach charge air duct (1) with special tool 11 8 670 to charge air cooler (2).
 Charge air ducts must audibly snap into place.
Fig. 77: Attaching Charge Air Duct With Special Tool 11 8 670 To Charge Air Cooler
Texts refer to and illustrations show the right side. The procedure is identical for the left side.
Reassemble the vehicle.

2007 BMW 335i
ACCESSORIES AND EQUIPMENT Cruise Control Systems - Repair Instructions
Cruise Control Systems - Repair Instructions
RADIO-CONTROLLED LOCKING
66 12 100 REMOVING AND INSTALLING/REPLACING SLIDE-IN UNIT FOR RADIO CONTROL
KEY
IMPORTANT: In the event of complaint "slide-in unit for radio-operated key jams or can not
be retained", carry out following checks before replacement:
1. Check both sides of plug connection of ribbon cable (2) to slide-in unit for
radio-operated key (1) for correct locking (3).
2. Check ribbon cable (4) for damage.
If required, lock plug connection of ribbon cable (2) correctly and carry out
function check.
If this rectifies fault pattern, do not replace slide-in unit for radio-operated key.
Fig. 1: Checking Ribbon Cable

Lift out cover (1) with special tool 00 9 340 at holding points (2) in direction of arrow.
2007 BMW 335i
Fig. 2: Identifying Special Tool (00 9 340), Trim And Retaining Points
Release screws (1).
Pull back slide-in unit for radio control key (2) with associated ribbon cable.
IMPORTANT: Carefully unlock ribbon cable plug connection.
Replace the ribbon cable if damaged.
The ribbon cable leads to:
 Control Unit For Car Access System

 Start/Stop Switch
Remove slide-in unit for radio control key (2).
Fig. 3: Identifying Radio Control Key And Mounting Screw

2007 BMW 335i
PARK DISTANCE CONTROL

66 20 508 REMOVING AND INSTALLING (REPLACING) CONTROL UNIT (PARK DISTANCE
CONTROL) (COUPE)
Protection).
 Remove Trim From Rear Apron

 Remove Right Luggage Compartment Trim Panel
Partly detach insulating mat (1) and feed out cable (2).
Fig. 4: Identifying Insulating Mat And Cable

Release screw (1).
Pull out device holder (2) and disconnect plug connection (3).
Unlock catch (4) and pull control unit out of device holder.
2007 BMW 335i
Fig. 5: Identifying Device Holder With Screw

Disconnect plug connection (1) and unlock catch (2).
Remove control unit (3).
Fig. 6: Identifying Plug Connection, Unlock Catch And Control Unit

Replacement:
Carry out Programming/Coding.
66 20 508 REMOVING AND INSTALLING (REPLACING) CONTROL UNIT (PARK DISTANCE

CONTROL) (CONVERTIBLE)
Protection).

2007 BMW 335i
 Remove panel for passenger compartment partition

Unlock catch (1) and remove control unit (2) from device carrier (3).
Fig. 8: Identifying Control Unit, Catch, And Device Carrier

Replacement:
Carry out Programming/Coding.
66 20 518 REMOVING AND INSTALLING/REPLACING AN ULTRASONIC TRANSDUCER AT

FRONT (OUTSIDE) (PARK DISTANCE CONTROL)

2007 BMW 335i
 Remove front wheel arch trim (front section)
Unlock retaining tabs (1) in direction of arrow and pull ultrasonic transducer (2) out of holder (3).
Fig. 9: Identifying Holder, Retaining Tabs And Ultrasonic Transducer

Installation:
Retaining hooks (1) of ultrasonic transducer (2) must engage exactly in mountings (3).
Fig. 10: Identifying Retaining Hooks, Ultrasonic Transducer And Mounting

Installation:
Make sure rubber ring (1) is correctly seated on ultrasonic transducer (2).
2007 BMW 335i
Fig. 11: Identifying Rubber Ring And Ultrasonic Transducer

66 20 520 REMOVING AND INSTALLING/REPLACING AN ULTRASONIC TRANSDUCER AT

FRONT (INSIDE) (PARK DISTANCE CONTROL)
Fig. 12: Identifying Retaining Tabs, Ultrasonic Transducer And Holder

Installation:
2007 BMW 335i
Fig. 13: Identifying Hooks, Mountings And Ultrasonic Transducer

Installation:

66 20 538 REMOVING AND INSTALLING/REPLACING A REAR (MIDDLE) ULTRASONIC

TRANSDUCER (PARK DISTANCE CONTROL)
Unlock retaining tabs (2) and pull ultrasonic transducer (3) out of holder.
2007 BMW 335i
Fig. 15: Identifying Plug Connection, Retaining Tabs And Ultrasonic Transducer
Installation:
Fig. 16: Identifying Retaining Hooks, Ultrasonic Transducer And Mountings

Installation:
2007 BMW 335i

66 20 540 REMOVING AND INSTALLING/REPLACING A REAR (LEFT/RIGHT) ULTRASONIC

TRANSDUCER (PARK DISTANCE CONTROL)
 N52:
 Remove Bottom Middle Cover
 N54:
 Remove Rear Bumper Trim
NOTE: On cars with N52 engines, the outer ultrasonic transducers are accessible from
below without having to remove the bumper trim.
Fig. 18: Identifying Retaining Tabs, Ultrasonic Transducer And Holder

2007 BMW 335i
Installation:
Fig. 19: Identifying Retaining Hooks, Ultrasonic Transducer And Mountings

Installation:

66 20 560 REMOVING AND INSTALLING/REPLACING REAR SIGNAL SENSOR (PARK

DISTANCE CONTROL)
Vehicles with HiFi or Top HiFi system:
No acoustic sensors fitted because the PDC control unit activates the respective speaker on the side of
obstruction.
2007 BMW 335i
66 20 565 REMOVING AND INSTALLING/REPLACING FRONT SIGNAL SENSOR (PARK

DISTANCE CONTROL)
 Remove Trim Panel For Pedal Assembly.
Fig. 21: Identifying Front Signal Sensor Plug Connection

Unclip signal sensor on both sides from fixture (1).
Installation:
Signal sensor (2) must snap audibly into retaining tabs.
Fig. 22: Identifying Signal Sensor And Fixture

2007 BMW 335i
ADAPTIVE CRUISE CONTROL

66 31 001 ADJUSTING ACC SENSOR
 36 1 100
 66 3 150
Unclip trim (1) at points (2) and remove towards front from bumper trim (3).
Fig. 23: Identifying Bumper Trim, Sensor Clipping Points And Sensor Trim
Installation:
Make sure trim (1) is correctly seated.
Locking hooks (2) must not be damaged.

2007 BMW 335i
Fig. 24: Identifying Locking Hooks And Trim

Carry out adjustment of ACC sensor (1) with special tool 66 3 150 by means of adjusting screws (2).
Fig. 25: Identifying Special Tool (66 3 150), ACC Sensor And Screws
Special tool required:
Active Cruise Control ACC adjusting device, complete.
Order number: 81 10 0 021 292
Consisting of:
1. Mirror, complete
2. Wheel laser
3. Slotted diaphragm
4. Control bracket (for initial installation of rail)
5. Rail
6. Setup and operating instructions (not shown)
2007 BMW 335i
Fig. 26: Identifying Mirror, Complete, Wheel Laser, Slotted Diaphragm, And Control Bracket
NOTE: A holder which is not included in the scope of delivery is required to support
the wheel laser. Use either the quick-action clamp from the existing KDS or ACC
wheel holder (36 1 100).
NOTE:  Follow manufacturer's instructions for ACC adjusting device.
NOTE: To adjust the ACC sensor, connect the BMW diagnosis system and fit the ACC
adjusting device.
Select ACC system in diagnosis. Start test module "ACC adjustment" (service
functions) and proceed in accordance with instructions.
Handle ACC adjusting device in accordance with mounting and operating

instructions provided with device.
66 31 006 REMOVING AND INSTALLING (REPLACING) ACC SENSOR
 00 9 317
 Remove Cover For ACC Sensor
IMPORTANT: Secure ACC sensor (2) against falling out.
Cover bumper in working area with adhesive tape (1).

2007 BMW 335i
Using special tool 00 9 317, unclip ACC sensor (2) from holders on both sides.
Installation:
ACC sensor must be felt and heard to snap into place.
Fig. 27: Identifying ACC Sensor, Adhesive Tape And Special Tool (00 9 317)
IMPORTANT: Secure ACC sensor (1) against falling out.
Fig. 28: Identifying ACC Sensor And Plug Connection

After installation:
 Carry out Programming/Coding.

 Carry out ACC Sensor Adjustment using BMW diagnostic system.
2007 BMW 335i
Replacement:
Check preliminary adjustment of ACC sensor (1).
If necessary, carry out preliminary adjustment at retaining pins (2).
 Measurement A: 43 ± 0.5 mm
Fig. 29: Identifying Retaining Pins, ACC Sensor And Measurement Areas
66 31 100 REMOVING AND INSTALLING/REPLACING LONGITUDINAL DYNAMICS MODULE
Protection).
 Remove Control Unit For Car Access System
Release bolts (1) and disconnect associated plug connection.
Remove longitudinal dynamics module (2).

2007 BMW 335i
Fig. 30: Identifying Longitudinal Dynamics Module And Bolts

6631... REPLACING SCREWS ON ACC SENSOR UNIT
 Remove ACC SENSOR
IMPORTANT: Visually inspect sensor housing for damage/leaks.

Replace ACC sensor if sensor housing is damaged .
Grip sensor housing (1) by screw in a vice (2).
Release screw by turning sensor housing (2).
IMPORTANT: After releasing screws, check sensor housing (1) again for damage.
Replace ACC sensor if sensor housing (1) is damaged.
Fig. 31: Griping Sensor Housing By Screw In Vice

2007 BMW 335i
NOTE: For purposes of clarity, graphic show ACC sensor holder removed.
Replace plastic nuts (1).
Fig. 32: Identifying Plastic Nuts

Carry out rough adjustment of ACC sensor (1) at adjusting screws (2).
 Measurement A [mm]: 42.5 to 43.5

2007 BMW 335i
Fig. 33: Identifying ACC Sensor With Adjusting Screws

After installation
 Adjust ACC SENSOR
REVERSING CAMERA
66 53... INSTRUCTIONS FOR ADAPTING ADJUSTMENT UNIT FOR REVERSING CAMERA
(CORGHI KDS QUICK-ACTION CLAMP)
The following operations should only be carried out when using the tool kit for calibrating the reversing camera
for the first time.
See for ordering conversion kit.
NOTE: The operation is described for the left-hand side; proceed in the same way for
the right-hand side.
Remove support plate (1) from spindle (2).

2007 BMW 335i
Replace spindle (2) by spindle (3).
Press support plate (1) on to spindle (3).
Fig. 34: Identifying Support Plate From Spindle

Release retaining clip (1).
Remove ball pin (2) from rod (3).
Fig. 35: Identifying Ball Pin From Rod

Fit new ball pin (1) on rod (2) and secure with retaining clip (3).
Fit ball pin (1) on CORGHI KDS quick-release clamp and secure.
2007 BMW 335i
Fig. 36: Identifying Ball Pin On CORGHI KDS Quick-Release

Remove all spacers (1) on cross bar (2).
NOTE: Follow the same procedure for calibrating the reversing camera.
Fig. 37: Identifying Spacers On Cross Bar

2007 BMW 335i
DTC INDEX 135i, 335i, 335xi, 535i & 535xi
DTC INDEX
135i, 335i, 335xi, 535i & 535xi
SELF-DIAGNOSTICS DTCS
SELF-DIAGNOSTICS DIAGNOSTIC TROUBLE CODE (DTC) LIST
DTC Description
DTC P0010 'A' Camshaft Position - Actuator Circuit/Open
(Bank 1) (SIG)
DTC P0012 'A' Camshaft Position - Timing Over-Retarded
(Bank 1) (PLAUS)
DTC P0013 'B' Camshaft Position - Actuator Circuit/Open
(Bank 1) (SIG)
DTC P0015 'B' Camshaft Position - Timing Over-Retarded
(Bank 1) (PLAUS)
DTC P0016 Crankshaft Position - Camshaft Position Correlation
(Bank 1 Sensor A) (MAX)
DTC P0017 Crankshaft Position - Camshaft Position Correlation
(Bank 1 Sensor B) (MAX)
DTC P0030 HO2S Heater Control Circuit (Bank 1 Sensor 1)
(SIG)
DTC P0031 HO2S Heater Control Circuit Low (Bank 1 Sensor
1) (MIN)
DTC P0032 HO2S Heater Control Circuit High (Bank 1 Sensor
1) (MAX)
(SIG)
2) (MIN)
2) (MAX)
DTC P0040 O2 Sensor Signals Swapped Bank 1 Sensor 1 / Bank
2 Sensor 1 (PLAUS)
DTC P0041 O2 Sensor Signals Swapped Bank 1 Sensor 2 / Bank
2 Sensor 2 (PLAUS)
(SIG)
1) (MIN)
1) (MAX)
(SIG)
2007 BMW 335i

2) (MIN)
2) (MAX)
DTC P0070 Ambient Air Temperature Sensor Circuit (SIG)
DTC P0071 Ambient Air Temperature Sensor
Range/Performance (PLAUS)
DTC P0072 Ambient Air Temperature Sensor Circuit Low
(MIN)
DTC P0073 Ambient Air Temperature Sensor Circuit High
(MAX)
DTC P0090 Fuel Pressure Regulator 1 Control Circuit (SIG)
DTC P0091 Fuel Pressure Regulator 1 Control Circuit Low
(MIN)
DTC P0092 Fuel Pressure Regulator 1 Control Circuit High
(MAX)
DTC P0100 Mass or Volume Air Flow 'A' Circuit (MAX)
DTC P0101 Mass or Volume Air Flow 'A' Circuit
Range/Performance (MAX)
DTC P0111 Intake Air Temperature Sensor 1 Circuit
Range/Performance (Bank 1) (PLAUS)
DTC P0112 Intake Air Temperature Sensor 1 Circuit Low (Bank
1) (MIN)
DTC P0113 Intake Air Temperature Sensor 1 Circuit High
(Bank 1) (MAX)
DTC P0117 Engine Coolant Temperature Sensor 1 Circuit Low
(MIN)
DTC P0118 Engine Coolant Temperature Sensor 1 Circuit High
(MAX)
DTC P0121 Throttle/Pedal Position Sensor/Switch 'A' Circuit
Low (MIN)
High (MAX)
DTC P0128 Coolant Thermostat (Coolant Temperature Below
Thermostat Regulating Temperature) (PLAUS)
DTC P0131 O2 Sensor Circuit Low Voltage (Bank 1 Sensor 1)
(MIN)
DTC P0132 O2 Sensor Circuit High Voltage (Bank 1 Sensor 1)
(MAX)
DTC P0133 O2 Sensor Circuit Slow Response (Bank 1 Sensor
1) (MAX)
DTC P0135 O2 Sensor Heater Circuit (Bank 1 Sensor 1) (MAX)
2007 BMW 335i
DTC P0135 O2 Sensor Heater Circuit (Bank 1 Sensor 1) (MIN)

(MIN)
(MAX)
2) (PLAUS)
DTC P0140 O2 Sensor Circuit No Activity Detected (Bank 1
Sensor 2) (SIG)
(MIN)
(MAX)
1) (MAX)
DTC P0155 O2 Sensor Heater Circuit (Bank 2 Sensor 1) (MIN)
(MIN)
(MAX)
2) (PLAUS)
DTC P0160 O2 Sensor Circuit No Activity Detected (Bank 2
Sensor 2) (SIG)
DTC P0171 System Too Lean (Bank 1) (MAX)
DTC P0171 System Too Lean (Bank 1) (SIG)
DTC P0172 System Too Rich (Bank 1) (MIN)
DTC P0172 System Too Rich (Bank 1) (PLAUS)
DTC P0174 System Too Lean (Bank 2) (MAX)
DTC P0174 System Too Lean (Bank 2) (SIG)
DTC P0175 System Too Rich (Bank 2) (MIN)
DTC P0175 System Too Rich (Bank 2) (PLAUS)
DTC P0190 Fuel Rail Pressure Sensor 'A' Circuit (MAX)
DTC P0192 Fuel Rail Pressure Sensor 'A' Circuit Low (MIN)
DTC P0201 Injector Circuit/Open - Cylinder 1 (MAX)
DTC P0201 Injector Circuit/Open - Cylinder 1 (PLAUS)
2007 BMW 335i

DTC P0221 Throttle/Pedal Position Sensor/Switch 'B' Circuit
Low (MIN)
High (MAX)
DTC P0234 Turbocharger/Supercharger 'A' Overboost Condition
(PLAUS)
DTC P0236 Turbocharger/Supercharger Boost Sensor 'A' Circuit
Low (MIN)
High (MAX)
DTC P0243 Turbocharger/Supercharger Wastegate Solenoid
'A' (SIG)
DTC P0245 Turbocharger/Supercharger Wastegate Solenoid 'A'
Low (MIN)
DTC P0246 Turbocharger/Supercharger Wastegate Solenoid 'A'
High (MAX)
DTC P0247 Turbocharger/Supercharger Wastegate Solenoid
'B' (SIG)
DTC P0249 Turbocharger/Supercharger Wastegate Solenoid 'B'
Low (MIN)
DTC P0250 Turbocharger/Supercharger Wastegate Solenoid 'B'
High (MAX)
DTC P0299 Turbocharger/Supercharger 'A' Underboost
Condition (MAX)
Condition (MAX)
Condition (PLAUS)
DTC P029A Cylinder 1 Balance - Fuel Trim at Max Limit (MIN)
DTC P029B Cylinder 1 Balance - Fuel Trim at Min Limit
(MAX)
DTC P029E Cylinder 2 Balance - Fuel Trim at Max Limit (MIN)
DTC P029F Cylinder 2 Balance - Fuel Trim at Min Limit
(MAX)
2007 BMW 335i
DTC P02A2 Cylinder 3 Balance - Fuel Trim at Max Limit (MIN)

DTC P02A3 Cylinder 3 Balance - Fuel Trim at Min Limit
(MAX)
DTC P02A6 Cylinder 4 Balance - Fuel Trim at Max Limit (MIN)
DTC P02A7 Cylinder 4 Balance - Fuel Trim at Min Limit
(MAX)
DTC P02AA Cylinder 5 Balance - Fuel Trim at Max Limit (MIN)
DTC P02AB Cylinder 5 Balance - Fuel Trim at Min Limit
(MAX)
DTC P02AE Cylinder 6 Balance - Fuel Trim at Max Limit
(MAX)
(MAX)
(MAX)
(MAX)
(MAX)
(MAX)
DTC P02AE Cylinder 6 Balance - Fuel Trim at Max Limit (MIN)
DTC P02AF Cylinder 6 Balance - Fuel Trim at Min Limit
(MAX)
DTC P0300 Random/Multiple Cylinder Misfire Detected
(MAX)
DTC P0300 Random/Multiple Cylinder Misfire Detected (MIN)
DTC P0300 Random/Multiple Cylinder Misfire Detected
(PLAUS)
DTC P0300 Random/Multiple Cylinder Misfire Detected (SIG)
DTC P0301 Cylinder 1 Misfire Detected (MAX)
DTC P0301 Cylinder 1 Misfire Detected (MIN)
DTC P0301 Cylinder 1 Misfire Detected (SIG)
2007 BMW 335i

DTC P0313 Misfire Detected With Low Fuel (MIN)
DTC P0326 Knock Sensor 1 Circuit Range/Performance (Bank 1
or Single Sensor) (PLAUS)
DTC P0327 Knock Sensor 1 Circuit Low (Bank 1 or Single
Sensor) (MIN)
DTC P0328 Knock Sensor 1 Circuit High (Bank 1 or Single
Sensor) (MAX)
DTC P0335 Crankshaft Position Sensor 'A' Circuit (MAX)
DTC P0335 Crankshaft Position Sensor 'A' Circuit (MIN)
DTC P0340 Camshaft Position Sensor 'A' Circuit (Bank 1 or
Single Sensor) (MAX)
DTC P0341 Camshaft Position Sensor 'A' Circuit
Range/Performance (Bank 1 or Single Sensor)
(MAX)
DTC P0344 Camshaft Position Sensor 'A' Circuit Intermittent
(Bank 1 or Single Sensor) (MAX)
DTC P0365 Camshaft Position Sensor 'B' Circuit (Bank 1)
(MAX)
DTC P0366 Camshaft Position Sensor 'B' Circuit
Range/Performance (Bank 1) (MAX)
DTC P0369 Camshaft Position Sensor 'B' Circuit Intermittent
(Bank 1) (MAX)
DTC P0370 Timing Reference High Resolution Signal
'A' (MAX)
DTC P0370 Timing Reference High Resolution Signal
'A' (MAX)
DTC P0370 Timing Reference High Resolution Signal 'A' (MIN)
DTC P0373 Timing Reference High Resolution Signal 'A'
Intermittent/Erratic Pulses (MAX)
DTC P0420 Catalyst System Efficiency Below Threshold (Bank
1) (MAX)
2007 BMW 335i
1) (MAX)
1) (MIN)
1) (MIN)
2) (MAX)
2) (MAX)
2) (MAX)
2) (MIN)
2) (MIN)
2) (MIN)
DTC P0440 Evaporative Emission System (PLAUS)
DTC P0441 Evaporative Emission System Incorrect Purge Flow
(SIG)
DTC P0442 Evaporative Emission System Leak Detected (small
leak) (MAX)
DTC P0444 Evaporative Emission System Purge Control Valve
Circuit Open (SIG)
DTC P0456 Evaporative Emission System Leak Detected (very
small leak) (MIN)
Circuit Low (MIN)
Circuit High (MAX)
DTC P0461 Fuel Level Sensor 'A' Circuit Range/Performance
(MAX)
DTC P0461 Fuel Level Sensor 'A' Circuit Range/Performance
(PLAUS)
DTC P0462 Fuel Level Sensor 'A' Circuit Low (MIN)
DTC P0463 Fuel Level Sensor 'A' Circuit High (MAX)
DTC P0475 Exhaust Pressure Control Valve (SIG)
DTC P0477 Exhaust Pressure Control Valve Low (MIN)
DTC P0478 Exhaust Pressure Control Valve High (MAX)
DTC P0480 Fan 1 Control Circuit (SIG)
DTC P0500 Vehicle Speed Sensor 'A' (SIG)
DTC P0503 Vehicle Speed Sensor 'A' Intermittent/Erratic/High
(PLAUS)
DTC P0506 Idle Air Control System RPM Lower Than
2007 BMW 335i
Expected (MIN)
DTC P0507 Idle Air Control System RPM Higher Than
Expected (MAX)
DTC P0512 Starter Request Circuit (MAX)
DTC P0512 Starter Request Circuit (MIN)
DTC P0512 Starter Request Circuit (SIG)
DTC P0520 Engine Oil Pressure Sensor/Switch Circuit (SIG)
DTC P0521 Engine Oil Pressure Sensor/Switch Range /
Performance (PLAUS)
DTC P0522 Engine Oil Pressure Sensor/Switch Low (MIN)
DTC P0523 Engine Oil Pressure Sensor/Switch High (MAX)
DTC P0524 Engine Oil Pressure Too Low (MIN)
DTC P053A Positive Crankcase Ventilation Heater Control
Circuit/Open (SIG)
DTC P053B Positive Crankcase Ventilation Heater Control
Circuit Low (MIN)
DTC P053C Positive Crankcase Ventilation Heater Control
Circuit High (MAX)
DTC P0545 Exhaust Gas Temperature Sensor Circuit Low
(Bank 1 Sensor 1) (MIN)
DTC P0546 Exhaust Gas Temperature Sensor Circuit High
(Bank 1 Sensor 1) (MAX)
DTC P0571 Brake Switch 'A' Circuit (PLAUS)
DTC P0597 Thermostat Heater Control Circuit/Open (SIG)
DTC P0598 Thermostat Heater Control Circuit Low (MIN)
DTC P0599 Thermostat Heater Control Circuit High (MAX)
DTC P0604 Internal Control Module Random Access Memory
(RAM) Error (MAX)
(RAM) Error (MIN)
(RAM) Error (MIN)
DTC P0605 Internal Control Module Read Only Memory
(ROM) Error (MAX)
DTC P0606 ECM/PCM Processor (SIG)
DTC P060C Internal Control Module Main Processor
Performance (PLAUS)
DTC P0620 Generator Control Circuit (MAX)
DTC P0620 Generator Control Circuit (SIG)
DTC P062F Internal Control Module EEPROM Error (PLAUS)
DTC P062F Internal Control Module EEPROM Error (SIG)
DTC P062F Internal Control Module EEPROM Error (SIG)
DTC P0645 A/C Clutch Relay Control Circuit (SIG)
2007 BMW 335i
DTC P0646 A/C Clutch Relay Control Circuit Low (MIN)

DTC P0647 A/C Clutch Relay Control Circuit High (MAX)
DTC P0668 PCM/ECM/TCM Internal Temperature Sensor
Circuit Low (MIN)
DTC P0669 PCM/ECM/TCM Internal Temperature Sensor
Circuit High (MAX)
DTC P0686 ECM/PCM Power Relay Control Circuit Low
(MIN)
DTC P0687 ECM/PCM Power Relay Control Circuit High
(MAX)
DTC P0691 Fan 1 Control Circuit Low (MIN)
DTC P0692 Fan 1 Control Circuit High (MAX)
DTC P0703 Brake Switch 'B' Circuit (PLAUS)
DTC P0831 Clutch Pedal Switch 'A' Circuit Low (MIN)
DTC P0832 Clutch Pedal Switch 'A' Circuit High (MAX)
DTC P0A14 Engine Mount 'A' Control Circuit/Open (SIG)
DTC P0A15 Engine Mount 'A' Control Circuit Low (MIN)
DTC P0A16 Engine Mount 'A' Control Circuit High (MAX)
DTC P0A3B Generator Over Temperature (MAX)
DTC P0A3B Generator Over Temperature (MAX)
DTC P104E Turbocharger Air Temperature Sensor 1 Input High
or Open Circuit (MAX)
DTC P104F Turbocharger Air Temperature Sensor 1 Input Low
(MIN)
DTC P1104 Differential Pressure Sensor Intake Manifold
Pressure Too Low (Bank 1) (MIN)
DTC P1105 Differential Pressure Sensor Intake Manifold
Pressure Too High (Bank 1) (MAX)
DTC P110D Throttle Position Sensor A and B
Range/Performance (MAX)
Range/Performance (MIN)
DTC P111E Intake Air Temperature Sensor 1 Maximum
Temperature Implausible (Bank 1) (MAX)
DTC P111F Intake Air Temperature Sensor 1 Minimum
Temperature Implausible (Bank 1) (MIN)
DTC P1124 Differential Pressure Sensor Intake Manifold Offset
(Bank 1) (PLAUS)
DTC P112C O2 Sensor Negative Current or Positive Current
Control Circuit/Open (Bank 1 Sensor 1) (MIN)
DTC P112C O2 Sensor Negative Current or Positive Current
2007 BMW 335i
Control Circuit/Open (Bank 1 Sensor 1) (SIG)

DTC P112D O2 Sensor Negative Current or Positive Current
Control Circuit/Open (Bank 2 Sensor 1) (MIN)
DTC P112D O2 Sensor Negative Current or Positive Current
Control Circuit/Open (Bank 2 Sensor 1) (SIG)
DTC P112E Manifold Absolute Pressure to Throttle Angle - Too
Low (MIN)
DTC P112F Manifold Absolute Pressure to Throttle Angle - Too
High (MAX)
DTC P1130 O2 Sensor Circuit Dynamic Test (Bank 1 Sensor 2)
(PLAUS)
(SIG)
(PLAUS)
(SIG)
DTC P114A Post Catalyst Fuel Trim Via Oxygen Sensor System
Too Rich (Bank 1) (MAX)
DTC P114B Post Catalyst Fuel Trim Via Oxygen Sensor System
Too Lean (Bank 1) (MIN)
DTC P114C Post Catalyst Fuel Trim Via Oxygen Sensor System
Too Rich (Bank 2) (MAX)
DTC P114D Post Catalyst Fuel Trim Via Oxygen Sensor System
Too Lean (Bank 2) (MIN)
DTC P114F Air Mass Flow Sensor Defective (MAX)
DTC P114F Air Mass Flow Sensor Defective (MIN)
DTC P115E Intake Air Temperature Sensor 1 Gradient
Implausible (Bank 1) (PLAUS)
DTC P116C Air Mass Flow Sensor Signal Range (MAX)
DTC P116E Air Mass Flow Sensor Signal Electrical (SIG)
DTC P1197 Differential Pressure Sensor Intake Manifold High
Input (Bank 1) (MAX)
DTC P1198 Differential Pressure Sensor Intake Manifold Low
Input (Bank 1) (MIN)
DTC P119A Manifold Absolute Pressure Sensor Circuit High
(Bank 1) (MAX)
DTC P119B Manifold Absolute Pressure Sensor Circuit Low
(Bank 1) (MIN)
DTC P119D Fuel Trim, Injector Aging Long-Term Adaptation
Too High (Bank l) (MIN)
DTC P119E Fuel Trim, Injector Aging Long-Term Adaptation
Too High (Bank 2) (MIN)
DTC P1214 Fuel Pump Speed Too High (MAX)
2007 BMW 335i
DTC P1215 Fuel Pump Speed Too Low (MIN)

DTC P1216 Fuel Pump Emergency Operation (SIG)
DTC P1217 Fuel Pump Overtemperature Condition (MAX)
DTC P1217 Fuel Pump Overtemperature Condition (MIN)
DTC P1217 Fuel Pump Overtemperature Condition (PLAUS)
DTC P1217 Fuel Pump Overtemperature Condition (SIG)
DTC P121C NOx Sensor Heater Control Circuit Shorted (Bank
1) (PLAUS)
DTC P121E NOx Sensor Linear Oxygen Sensor Signal
Circuit/Open (Bank 1) (SIG)
DTC P121F NOx Sensor Linear Oxygen Sensor Signal Circuit
Shorted (Bank 1) (PLAUS)
DTC P122C NOx Sensor Circuit Shorted (Bank 1) (PLAUS)
DTC P122E NOx Sensor Binary Oxygen Sensor Signal
Circuit/Open (Bank 1) (SIG)
DTC P122F NOx Sensor Binary Oxygen Sensor Signal Circuit
Shorted (Bank 1) (PLAUS)
DTC P1230 Fuel Pump Relay Primary Circuit (SIG)
DTC P1234 Fuel Pump Relay Primary Circuit Low (MIN)
DTC P1236 Fuel Pump Relay Primary Circuit High (MAX)
DTC P1244 Fuel Pump Emergency Cut-Off (SIG)
DTC P126E NOx Sensor Signal Binary Oxygen Sensor Signal
Too Rich During Deceleration Test (Bank 1)
(MAX)
DTC P126F NOx Sensor Signal Linear Oxygen Sensor Signal
Too Rich During Deceleration Test (Bank 1) (MIN)
DTC P127A NOx Sensor Signal Too High During Deceleration
Test (Bank 1) (PLAUS)
DTC P127B NOx Sensor Signal Too Low During Deceleration
Test (Bank 1) (SIG)
2007 BMW 335i
DTC P1298 Serial Communication NOx Sensor (Bank 1) (SIG)

DTC P1299 Serial Communication NOx Sensor (Bank 2) (SIG)
DTC P129B Manifold Absolute Pressure Sensor Afterrunning
Diagnosis Range/Performance (PLAUS)
DTC P1300 Camshaft Position Sensor 'A' Segment Timing Error
(Bank 1) (MAX)
DTC P1301 Ignition Monitoring Cylinder 1 Spark Duration Too
Short (MIN)
Short (MIN)
Short (MIN)
Short (MIN)
Short (MIN)
Short (MIN)
DTC P130A Camshaft Position Sensor 'B' Segment Timing Error
(Bank 1) (MAX)
DTC P1327 Knock Sensor 2 Circuit Low Input (Bank 1) (MIN)
DTC P1328 Knock Sensor 2 Circuit High Input (Bank 1) (MAX)
DTC P135B Knock Sensor 2 Circuit Range/Performance (Bank
1) (PLAUS)
DTC P1383 Ignition Monitoring Malfunction (PLAUS)
DTC P1396 Crankshaft Position Sensor Segment Timing
Plausibility (MIN)
DTC P1407 Fuel Level Signal 1 (PLAUS)
DTC P1408 Fuel Level Signal 2 (PLAUS)
DTC P140E Cylinder Injection Cut-Off, Fuel Level Too Low
(PLAUS)
DTC P1415 Mass or Volume Air Flow Too Low (MIN)
DTC P1417 Throttle Control Incorrect Air Supply (SIG)
DTC P1424 Mass or Volume Air Flow Too High (MAX)
DTC P142E Cylinder Injection Cut-Off, Pressure Too Low in
High-Pressure System (MAX)
DTC P142F Cylinder Injection Cut-Off, Pressure Too Low in
Low-Pressure System (MIN)
DTC P1434 Diagnostic Module Tank Leakage (DM-TL) (SIG)
DTC P1447 Diagnostic Module Tank Leakage (DM-TL) Pump
Current Too High during Switching Solenoid Test
(PLAUS)
Current Too Low (MIN)
2007 BMW 335i

Current Too High (MAX)
DTC P14C0 Fan Mechanical or Hardware Defect (PLAUS)
DTC P14C2 DISA (Differentiated Intake Manifold) Actuator 1
Mechanical or Hardware Defect (PLAUS)
DTC P14C3 DISA (Differentiated Intake Manifold) Actuator 2
Mechanical or Hardware Defect (PLAUS)
DTC P14C4 Radiator Shutter (Upper) Mechanical (MIN)
DTC P14C5 Radiator Shutter (Upper) Hardware Defect (MAX)
DTC P14C6 Radiator Shutter (Lower) Electrical (MAX)
DTC P150A Battery Sensor BSD (Bit Serial Data Interface)
Extended Communication Circuit (MAX)
DTC P150B Battery Sensor BSD (Bit Serial Data Interface)
Communication Circuit (SIG)
DTC P150B Battery Sensor BSD (Bit Serial Data Interface)
Communication Circuit (SIG)
DTC P150C Battery Sensor Firmware Implausible (PLAUS)
DTC P150D Battery Sensor Temperature Error (MAX)
DTC P150E Battery Sensor Voltage Error (SIG)
DTC P150F Battery Sensor Current Error (PLAUS)
DTC P1511 DISA (Differentiated Intake Manifold) Control
Circuit Electrical (MAX)
Circuit Electrical (MIN)
Circuit Electrical (SIG)
Circuit Electrical (SIG)
Circuit Signal Low (MIN)
Circuit Signal Low (MIN)
Circuit Signal High (MAX)
Circuit Signal High (MAX)
DTC P1515 Engine Off Timer Plausibility (PLAUS)
DTC P151A Battery Sensor Terminal 15/30 Wakeup Circuit
(MAX)
DTC P151B Battery Sensor Wakeup Circuit (PLAUS)
DTC P151C Battery Sensor System Error (SIG)
DTC P1521 Engine Oil Quality Sensor Communication Error
(SIG)
2007 BMW 335i
DTC P1540 Driving Dynamics Control Switch High Input

(MAX)
DTC P1541 Driving Dynamics Control Switch Low Input (MIN)
DTC P1551 Engine Off Timer Timeout (SIG)
DTC P1553 Engine Position System 'B' Performance (Bank 1)
(MAX)
DTC P1554 Engine Position System 'A' Performance (Bank 1)
(MAX)
DTC P155A Multifunction Steering Wheel (MFL) Interface,
Toggle-Bit Fault (MAX)
Toggle-Bit Fault (MIN)
Toggle-Bit Fault (PLAUS)
DTC P1561 Cold Start Idle Air Control System RPM Lower
Than Expected (Bank 1) (MIN)
DTC P1562 Cold Start Idle Air Control System RPM Higher
Than Expected (Bank 1) (MAX)
DTC P1563 Multifunction Steering Wheel (MFL) Rocker
Switch Defective (PLAUS)
DTC P1576 Multifunction Steering Wheel (MFL) Interface, Bit
Error (PLAUS)
DTC P1582 Oil Pump Circuit High (MAX)
DTC P1583 Oil Pump Circuit Low (MIN)
DTC P1584 Oil Pump Circuit Open (SIG)
DTC P1586 Engine Oil Quality Sensor Temperature
Measurement (MAX)
DTC P1587 Engine Oil Quality Sensor Level Measurement
(MIN)
DTC P1588 Engine Oil Quality Sensor Permeability
Measurement (PLAUS)
DTC P15A1 Engine Oil Pressure Control, Mechanical, Solenoid
Valve Sticking In Fully Energized Position
(Minimum Oil Pressure) (MAX)
DTC P15A2 Engine Oil Pressure Control, Mechanical, Solenoid
Valve Sticking In De-Energized Position
(Maximum Oil Pressure) (MIN)
DTC P15A3 Engine Oil Pressure Too High (MAX)
DTC P15A6 Engine Oil Pressure Too High Before Start (MAX)
DTC P15A7 Engine Oil Pressure Too Low Before Start (MIN)
DTC P15A9 Energy-Saving Mode - Transportation Mode (MIN)
DTC P15AA Turbocharger Leak in Supercharger System
(PLAUS)
DTC P15B0 Terminal 15 Sense Circuit Input High (MAX)
2007 BMW 335i
DTC P15B1 Terminal 15 Sense Circuit Input Low (MIN)

DTC P15B2 Terminal 15 Sense Circuit CAS Error (SIG)
DTC P15B3 Terminal 15 Sense Circuit Range/Performance
(PLAUS)
DTC P160A Powermanagement Exhaustive Discharge (MIN)
DTC P160B Powermanagement Defective (PLAUS)
DTC P160C Powermanagement Overvoltage (MAX)
DTC P160D Powermanagement Undervoltage (MIN)
DTC P160E Powermanagement Operation Without Battery
(SIG)
DTC P160F Powermanagement No-Load Current Error
(PLAUS)
DTC P1618 Control Module Self-Test, AD-Converter
Monitoring (PLAUS)
DTC P1625 Pedal Position Sensor Potentiometer Supply
Channel 2 Electrical (PLAUS)
DTC P1632 Throttle Valve Adaptation Conditions Not Met
(Bank 1) (MAX)
DTC P1633 Throttle Valve Adaptation Limp-Home Position
Unknown (Bank 1) (MIN)
DTC P1634 Throttle Valve Adaptation Spring Test Failed (Bank
1) (MAX)
DTC P1635 Throttle Valve Adaptation Lower Mechanical Stop
not Adapted (Bank 1) (MAX)
DTC P1636 Throttle Valve Control Circuit (Bank 1) (SIG)
DTC P1637 Throttle Valve Position Control, Control Deviation
(Bank 1) (MAX)
DTC P1638 Throttle Valve Position Control Throttle Stuck
Temporarily (Bank 1) (MAX)
DTC P1639 Throttle Valve Position Control Throttle Stuck
Permanently (Bank 1) (MAX)
DTC P1644 Throttle Valve Adaptation Stop Relearning Lower
Mechanical Stop (Bank 1) (PLAUS)
DTC P164C Pedal Position Sensor Potentiometer Supply
Channel Electrical (PLAUS)
DTC P164E Throttle Deicing Stuck in Closing Direction (MAX)
DTC P164F Throttle Deicing Stuck in Opening Direction (MIN)
DTC P165A EWS (Electronic Immobilizer) Interface to ECM,
Hardware Error (MAX)
DTC P165B EWS (Electronic Immobilizer) Interface to ECM,
Checksum Error (PLAUS)
DTC P165C EWS (Electronic Immobilizer) Data, No Available
Storage Possibility (MAX)
DTC P165D EWS (Electronic Immobilizer) Data, Faulty Release
2007 BMW 335i
Code Storage (MIN)

DTC P165E EWS (Electronic Immobilizer) Data, Checksum
Error (PLAUS)
DTC P165F Internal Control Module Measurement Error
Oxygen Sensor Heating (Bank 1, Sensor 1) (SIG)
DTC P1660 EWS (Electronic Immobilizer) Telegram Error
(MIN)
DTC P1661 Timeout EWS (Electronic Immobilizer) - Telegram
(SIG)
DTC P1667 EWS (Electronic Immobilizer) Start Value not yet
Programmed (MIN)
DTC P1667 EWS (Electronic Immobilizer) Start Value not yet
Programmed (PLAUS)
DTC P1668 EWS (Electronic Immobilizer) Start Value
Destroyed (SIG)
DTC P166A Control Module Self-Test, LDM (Longitudinal
Dynamics Management) Monitoring (SIG)
DTC P166B LDM (Longitudinal Dynamics Management)
Torque Request Inspite of Brake Signal (MAX)
DTC P166C LDM (Longitudinal Dynamics Management)
Torque Request Implausible (PLAUS)
DTC P1675 Throttle Valve Actuator Start Test Re-Adaptation
Required (MAX)
DTC P167B Throttle Heating Relay Circuit Input High (MAX)
DTC P167C Throttle Heating Relay Circuit Input Low (MIN)
DTC P167D Throttle Heating Relay Circuit (SIG)
DTC P1694 Throttle Valve Actuator Start Test Spring Test and
Limp-Home Position Failed (SIG)
DTC P169A Throttle Valve Actuator Start Test Limp-Home
Position Failed (MIN)
DTC P16A0 Internal Control Module Memory Check Sum Error
in Boot Software (MAX)
in Application Software (MIN)
in Data (SIG)
DTC P16A3 Internal Control Module Non-Volatile Memory
(NVMY) Error (MAX)
2007 BMW 335i
DTC P16A4 Timeout Control Module Knock Sensor SPI-Bus

(SIG)
DTC P16A5 Timeout Control Module Multiple Output Stage
SPI-Bus (SIG)
DTC P16A6 Control Module Self-Test, Cruise Control
Monitoring (MAX)
DTC P16A9 Control Module Self-Test, Speed Monitoring Reset
(PLAUS)
DTC P16B0 Control Module Self-Test, Pedal Position Sensor
Monitoring (PLAUS)
DTC P16B1 Control Module Self-Test, Idle Air Control System
Integrated Component Plausibility (SIG)
DTC P16B2 Control Module Self-Test, Idle Air Control System
PD-Component Plausibility (PLAUS)
DTC P16B3 Control Module Self-Test, MSR (Engine-Drag-
Torque Control) Monitoring (MAX)
DTC P16B4 Control Module Self-Test, DCC (Dynamic Cruise
Control) Monitoring (MIN)
DTC P16B5 Control Module Self-Test, AMT (Automatic
Manual Transmission) Monitoring (SIG)
DTC P16B6 Control Module Self-Test, ETC Monitoring
(PLAUS)
DTC P16B7 Control Module Self-Test, Clutch Torque
Monitoring Maximum Value Plausibility (MAX)
DTC P16B8 Control Module Self-Test, Clutch Torque
Monitoring Minimum Value Plausibility (MIN)
DTC P16B9 Control Module Self-Test, Torque Loss Monitoring
(SIG)
DTC P16C0 Control Module Self-Test, Driving Dynamics
Control Switch Monitoring (PLAUS)
DTC P16C1 Control Module Self-Test, Torque Monitoring
Current Indicated Value Plausibility (PLAUS)
DTC P16C1 Control Module Self-Test, Torque Monitoring
Current Indicated Value Plausibility (PLAUS)
DTC P16C2 Control Module Self-Test, Speed Limitation
Monitoring (PLAUS)
DTC P16C5 Main Relay Switching Delay (MIN)
DTC P16C6 CAN Timeout BSD (Bit Serial Data Interface)
(MAX)
(MAX)
(MAX)
2007 BMW 335i
(MIN)
(MIN)
(PLAUS)
(PLAUS)
(SIG)
(SIG)
(SIG)
(SIG)
DTC P2067 Fuel Level Sensor 'B' Circuit Low (MIN)
DTC P2068 Fuel Level Sensor 'B' Circuit High (MAX)
DTC P2088 'A' Camshaft Position Actuator Control Circuit Low
(Bank 1) (MIN)
DTC P2089 'A' Camshaft Position Actuator Control Circuit High
(Bank 1) (MAX)
DTC P2090 'B' Camshaft Position Actuator Control Circuit Low
(Bank 1) (MIN)
DTC P2091 'B' Camshaft Position Actuator Control Circuit High
(Bank 1) (MAX)
DTC P2096 Post Catalyst Fuel Trim System Too Lean (Bank 1)
(MIN)
DTC P2097 Post Catalyst Fuel Trim System Too Rich (Bank 1)
(MAX)
DTC P2098 Post Catalyst Fuel Trim System Too Lean (Bank 2)
(MIN)
DTC P2099 Post Catalyst Fuel Trim System Too Rich (Bank 2)
(MAX)
DTC P2120 Throttle/Pedal Position Sensor/Switch 'D' Circuit
(PLAUS)
Low (MIN)
High (MAX)
DTC P2127 Throttle/Pedal Position Sensor/Switch 'E' Circuit
Low (MIN)
DTC P2128 Throttle/Pedal Position Sensor/Switch 'E' Circuit
High (MAX)
DTC P2138 Throttle/Pedal Position Sensor/Switch 'D' / 'E'
2007 BMW 335i
Voltage Correlation (PLAUS)

DTC P213F Fuel Pump System Fault - Forced Engine Shutdown
(SIG)
DTC P2183 Engine Coolant Temperature Sensor 2 Circuit
DTC P2184 Engine Coolant Temperature Sensor 2 Circuit Low
(MIN)
DTC P2185 Engine Coolant Temperature Sensor 2 Circuit High
(MAX)
DTC P2187 System Too Lean at Idle (Bank 1) (MAX)
DTC P2188 System Too Rich at Idle (Bank 1) (MIN)
DTC P2189 System Too Lean at Idle (Bank 2) (MAX)
DTC P2190 System Too Rich at Idle (Bank 2) (MIN)
DTC P2191 System Too Lean at Higher Load (Bank 1) (MIN)
DTC P2192 System Too Rich at Higher Load (Bank 1) (MAX)
DTC P2193 System Too Lean at Higher Load (Bank 2) (MIN)
DTC P2194 System Too Rich at Higher Load (Bank 2) (MAX)
DTC P2195 O2 Sensor Signal Biased/Stuck Lean (Bank 1
Sensor 1) (MAX)
DTC P2196 O2 Sensor Signal Biased/Stuck Rich (Bank 1 Sensor
1) (MAX)
Sensor 1) (MAX)
1) (MAX)
DTC P2200 NOx Sensor Circuit (Bank 1) (SIG)
DTC P2205 NOx Sensor Heater Control Circuit/Open (Bank 1)
(SIG)
DTC P2228 Barometric Pressure Circuit Low (MIN)
DTC P2229 Barometric Pressure Circuit High (MAX)
DTC P2243 O2 Sensor Reference Voltage Circuit/Open (Bank 1
Sensor 1) (MAX)
DTC P2247 O2 Sensor Reference Voltage Circuit/Open (Bank 2
Sensor 1) (MAX)
Sensor 2) (MIN)
2) (MAX)
Sensor 2) (MIN)
2) (MAX)
DTC P2297 O2 Sensor Out of Range During Deceleration (Bank
2007 BMW 335i
1 Sensor 1) (MAX)
DTC P2298 O2 Sensor Out of Range During Deceleration (Bank
2 Sensor 1) (MAX)
DTC P2299 Brake Pedal Position / Accelerator Pedal Position
Incompatible (PLAUS)
DTC P2301 Ignition Coil 'A' Primary Control Circuit High
(MAX)
DTC P2304 Ignition Coil 'B' Primary Control Circuit High
(MAX)
DTC P2307 Ignition Coil 'C Primary Control Circuit High
(MAX)
DTC P2310 Ignition Coil 'D' Primary Control Circuit High
(MAX)
DTC P2313 Ignition Coil 'E' Primary Control Circuit High
(MAX)
DTC P2316 Ignition Coil 'F' Primary Control Circuit High
(MAX)
DTC P2400 Evaporative Emission System Leak Detection Pump
Control Circuit/Open (SIG)
Control Circuit Low (MIN)
Control Circuit High (MAX)
DTC P240A Evaporative Emission System Leak Detection Pump
Heater Control Circuit/Open (SIG)
DTC P240B Evaporative Emission System Leak Detection Pump
Heater Control Circuit Low (MIN)
DTC P240C Evaporative Emission System Leak Detection Pump
Heater Control Circuit High (MAX)
DTC P2414 O2 Sensor Exhaust Sample Error (Bank 1 Sensor 1)
(MAX)
DTC P2415 O2 Sensor Exhaust Sample Error (Bank 2 Sensor 1)
(MAX)
DTC P2418 Evaporative Emission System Switching Valve
Control Circuit/Open (SIG)
Control Circuit Low (MIN)
Control Circuit High (MAX)
DTC P250A Engine Oil Level Sensor Circuit (SIG)
DTC P250B Engine Oil Level Sensor Circuit Range/Performance
(PLAUS)
DTC P250F Engine Oil Level Too Low (MIN)
DTC P252A Engine Oil Quality Sensor Circuit (SIG)
2007 BMW 335i
DTC P2541 Low Pressure Fuel System Sensor Circuit Low

(MIN)
DTC P2542 Low Pressure Fuel System Sensor Circuit High
(MAX)
DTC P2626 O2 Sensor Pumping Current Trim Circuit/Open
(Bank 1 Sensor 1) (PLAUS)
DTC P2629 O2 Sensor Pumping Current Trim Circuit/Open
(Bank 2 Sensor 1) (PLAUS)
DTC P3003 Fuel Rail Pressure Flow-Rate-Controlled, Pressure
Too High (MAX)
DTC P3004 Fuel Rail Pressure Flow-Rate-Controlled, Maximum
Pressure Exceeded (MIN)
DTC P300A Controlled Air Guiding Circuit High (MAX)
DTC P300B Controlled Air Guiding Circuit Low (MIN)
DTC P300C Controlled Air Guiding Circuit (SIG)
DTC P3022 O2 Sensor Disturbed SPI Communication to
WRAF-IC (Bank 1 Sensor 1) (MIN)
DTC P3023 O2 Sensor Disturbed SPI Communication to
WRAF-IC (Bank 2 Sensor 1) (MIN)
DTC P3024 O2 Sensor Initialization Error WRAF-IC (Bank 1
Sensor 1) (MAX)
DTC P3025 O2 Sensor Initialization Error WRAF-IC (Bank 2
Sensor 1) (MAX)
DTC P3026 O2 Sensor Operating Temperature not Reached
DTC P3090 Fuel Rail Pressure Flow-Rate-Controlled, Minimum
Pressure Fallen Below (SIG)
DTC P3094 Fuel Low Pressure System Pressure Too High
(MAX)
DTC P3095 Fuel Low Pressure System Maximum Pressure
Exceeded (MIN)
DTC P3096 Fuel Low Pressure System Minimum Pressure
Fallen Below (SIG)
DTC P3101 Cylinder 1 High Pressure Injector Low Side Circuit
Low (PLAUS)
High (MIN)
2007 BMW 335i
Low (PLAUS)
High (MIN)
Low (PLAUS)
DTC P310B Cylinder 1 High Pressure Injector Low Side/High
Side Electrical (MIN)
Side Electrical (SIG)
DTC P310E Cylinder 2 High Pressure Injector Low Side/High
High (MIN)
Low (PLAUS)
High (MIN)
Low (PLAUS)
High (MIN)
Low (MAX)
Low (MAX)
Low (MIN)
Low (MIN)
Low (PLAUS)
Low (PLAUS)
2007 BMW 335i
Low (SIG)
Low (SIG)
Low (SIG)
High (MIN)
DTC P3149 Cylinder 1 High Pressure Injector High Side Circuit
Low (MAX)
High (SIG)
Low (MAX)
High (SIG)
Low (MAX)
High (SIG)
Low (MAX)
High (SIG)
Low (MAX)
High (SIG)
Low (MAX)
High (SIG)
DTC P316A Engine Coolant Temperature Signal Stuck High
(PLAUS)
DTC P3194 Fuel Pressure Control Basic Characteristic Curve
Adaptation 1 Out of Range (MAX)
DTC P3196 Cold Start Radiator Coolant Temperature Sensor
2007 BMW 335i
Signal High (MAX)

DTC P3197 Radiator Coolant Temperature Gradient Too High
(PLAUS)
DTC P3198 Engine Coolant Temperature 1 Gradient Too High
(PLAUS)
DTC P3199 Engine Coolant Temperature Signal Stuck (PLAUS)
DTC P319A Fuel Pressure Control Min. Characteristic Curve
Adaptation 1 Out of Range (MIN)
Adaptation 1 Out of Range (SIG)
DTC P3202 Powertrain CAN, CAN Chip Cut-Off (SIG)
DTC P3205 Local CAN, CAN Chip Cut-Off (SIG)
DTC P321E Ambient Pressure Sensor Maximum Pressure
Implausible (MAX)
DTC P321F Ambient Pressure Sensor Minimum Pressure
Implausible (MIN)
Implausible (PLAUS)
Implausible (PLAUS)
DTC P3223 Generator Mechanical (MAX)
DTC P3223 Generator Mechanical (PLAUS)
DTC P3226 E-Box Control Circuit Fan High Input (MAX)
DTC P3227 E-Box Control Circuit Fan Low Input (MIN)
2007 BMW 335i
DTC P3228 E-Box Control Circuit Fan Open Circuit (SIG)

DTC P3235 Control Module Monitoring Version Coding
Plausibility (PLAUS)
DTC P323F Control Module Monitoring Fuel Volume, Air
Mass/Lambda - Injected Fuel Volume Correlation
(PLAUS)
DTC P324A Generator Type Implausible (MAX)
DTC P324C Generator Over Temperature Calculated (MAX)
DTC P324E Generator Regulator Type Implausible (MAX)
DTC P3255 Generator Voltage in Starting Phase above
Threshold (MAX)
DTC P3259 Control Module Monitoring Fuel Volume, Lambda
Implausible to Operating Mode
(Homogeneous/Stratified Mode) (SIG)
DTC P325A Generator Electrical Error Calculated (MAX)
DTC P3283 Fuel Pressure Control Adaptive Fuel Volume Out of
Range (Bank 1) (MAX)
DTC P3284 Fuel Pressure Control Calculation Adaptive Fuel
Volume Implausible (Bank 1) (MIN)
DTC U0137 Lost Communication With Trailer Brake Control
Module (SIG)
DTC U0167 Lost Communication With Vehicle Immobilizer
Control Module (SIG)
DTC U1101 Lost Communication With Ambient
Temperature/Relative Time (SIG)
DTC U1102 Message Monitoring Actuation Cruise Control/ACC
Alive Check (MIN)
DTC U1103 Lost Communication With Actuation Cruise
Control/ACC (SIG)
DTC U1104 Message Monitoring Actuation Cruise Control/ACC
Check Sum Error (PLAUS)
DTC U1105 Message Monitoring Torque Request ACC Alive
Check (MIN)
DTC U1106 Lost Communication With Torque Request ACC
(SIG)
DTC U1107 Message Monitoring Torque Request ACC Check
Sum Error (PLAUS)
DTC U1108 Message Monitoring Torque Request Steering Alive
Check (MIN)
DTC U1108 Message Monitoring Torque Request Steering Alive
Check (MIN)
DTC U1109 Lost Communication With Torque Request Steering
(SIG)
DTC U1109 Lost Communication With Torque Request Steering
2007 BMW 335i
(SIG)
DTC U110A Message Monitoring Torque Request Steering
DTC U110A Message Monitoring Torque Request Steering
DTC U110B Message Monitoring Torque Request DSC Alive
Check (MIN)
DTC U110C Lost Communication With Torque Request DSC
(SIG)
DTC U110D Message Monitoring Torque Request DSC Check
Sum Error (PLAUS)
DTC U110E Message Monitoring Torque Request ETC Alive
Check (MIN)
DTC U110E Message Monitoring Torque Request ETC Alive
Check (MIN)
DTC U110F Lost Communication With Torque Request ETC
(SIG)
DTC U110F Lost Communication With Torque Request ETC
(SIG)
DTC U1110 Message Monitoring Torque Request ETC Check
Sum Error (MIN)
Sum Error (MIN)
Sum Error (PLAUS)
Sum Error (PLAUS)
Sum Error (PLAUS)
Sum Error (PLAUS)
Sum Error (SIG)
Sum Error (SIG)
Sum Error (SIG)
DTC U1114 Message Monitoring Vehicle Mode Status Alive
Check (MIN)
DTC U1115 Lost Communication With Vehicle Mode Status
(SIG)
DTC U1116 Message Monitoring Vehicle Mode Status Check
Sum Error (PLAUS)
DTC U1118 Lost Communication With Speed (SIG)
2007 BMW 335i
DTC U111A Lost Communication With Transmission Data (SIG)

DTC U111B Lost Communication With Transmission Data2
(SIG)
DTC U111C Lost Communication With Mileage/Range (SIG)
DTC U111D Message Monitoring Terminal Status Alive Check
(MIN)
DTC U111E Lost Communication With Terminal Status (SIG)
DTC U111F Message Monitoring Terminal Status Check Sum
Error (PLAUS)
DTC U1120 Lost Communication With Steering Wheel Angle
(SIG)
DTC U1121 Lost Communication With Power Management
Battery Voltage (SIG)
DTC U1122 Lost Communication With Power Management
Charge Voltage (SIG)
DTC U1123 Message Monitoring ARS- Module Status Alive
Check (MIN)
DTC U1124 Lost Communication With ARS-Module Status
(SIG)
DTC U1126 Lost Communication With DSC Status (SIG)
DTC U1128 Lost Communication With EKP (Electrical Fuel
Pump) Status (SIG)
DTC U1129 Lost Communication With Reverse Status (SIG)
DTC U112A Message Monitoring Instrument Pack Status Alive
Check (MIN)
DTC U112B Lost Communication With Instrument Pack Status
(SIG)
DTC U112C Lost Communication With Heat Flow/Load
Moment A/C (SIG)
DTC U112D Lost Communication With Control Crash Cut-Off
EKP (Electrical Fuel Pump) (SIG)
DTC U1130 Lost Communication With Radiator Shutter (Upper)
(PLAUS)
DTC U1132 Lost Communication With Generator via BSD (Bit
Serial Data Interface) (MAX)
DTC U1132 Lost Communication With Generator via BSD (Bit
Serial Data Interface) (SIG)
DTC U1134 Lost Communication With Lamp Status (SIG)
DTC U1135 Lost Communication With Status Water Valve
(SIG)
DTC U113A Lost Communication With Central Locking System
Status (SIG)
DTC U113C Lost Communication With Time/Date (SIG)
DTC U113D Lost Communication With Wheel Torque
2007 BMW 335i
Management Request/Driveline (SIG)

DTC U113E Lost Communication With Display Transmission
Data (SIG)
DTC U1160 Lost Communication With Message 2 TCM (SIG)
DTC U1161 Message Monitoring 3 TCM Alive Check (MIN)
DTC U1162 Message Monitoring 3 TCM Check Sum Error
(PLAUS)
DTC U1166 Message Monitoring EWS (Electronic Immobilizer)
- Frame Error (MIN)
2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi
2007 BMW
328i, 328xi, 335i & 335xi
BUZZERS, RELAYS & TIMERS

BUZZERS, RELAYS & TIMERS LOCATION
Component Location
A/C Compressor Relay (K19) Near A/C compressor.
DME Relay (K6300) Right rear of engine compartment. See Fig. 3.
Engine Breather Heating Relay (K6539) Right rear of engine compartment. See Fig. 17.
Fuel Injectors Relay (K6327) Right rear of engine compartment. See Fig. 3.
Fuel Pump Relay (K96) In junction box (A4010). See Fig. 1.
Headlight Washer Relay (K6) In junction box (A4010). See Fig. 2.
Horn Relay (K2) In junction box (A4010). See Fig. 1.
Rear Window Defroster Relay (K13) In junction box (A4010). See Fig. 1.
Rear Wiper Relay (K91) In junction box (A4010). See Fig. 1.
Secondary Air Pump Relay (K6304) In junction box (A4010). See Fig. 2.
Terminal 15 Relay (I01069) In junction box (A4010). See Fig. 1.
Terminal 30G Relay (I01068) In junction box (A4010). See Fig. 2.
VVT Relay (K6319) Right rear of engine compartment. See Fig. 4.
Wiper Relay 1 (K36) In junction box (A4010). See Fig. 2.
Wiper Relay 2 (K37) In junction box (A4010). See Fig. 2.
CIRCUIT PROTECTION DEVICES

CIRCUIT PROTECTION DEVICES LOCATION
Component Location
E Box Right rear of engine compartment.
Junction Box (A4010) Under right side of dash. See Fig. 27.
Junction Box Electronics (A4010a) Under right side of dash. See Fig. 27.
Rear Fuse Holder (A46) Right side of rear compartment. See Fig. 5.
CONTROL UNITS
CONTROL UNITS LOCATION
Component Location
Accelerator Pedal Module (B10) Part of Accelerator pedal. See Fig. 23.
Active Cruise Control (A144a) Center of front bumper. See Fig. 28.
Active Steering (A467) Behind left front wheel. See Fig. 18.
Car Access System (A149a) Under left side of dash. See Fig. 12.
Comfort Access Control Module (A215) Right side of rear compartment. See Fig. 16.
2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi
DME Control Module (A6000) Right rear of engine compartment. See Fig. 20.
Driver's Seat Heating Module (A187a) Under driver seat. See Fig. 14.
Driver's Seat Module (A187) Under driver seat. See Fig. 15.
Dynamic Stability Control (DSC) (A65a) Left rear of engine compartment. See Fig. 9.
Electronically Controlled Fuel Pump (A13663) In right rear side interior panel. See Fig. 21.
Electronic Power Steering (EPS) (A60233) Under vehicle, near right front wheel. See Fig. 25.
Footwell Module (A4011) Under left side of dash. See Fig. 19.
Heating/Air Conditioning System (A11a) Center of dash, above radio. See Fig. 22.
Independent Auxiliary Heater Control Module (A14) Left side of front bumper. See Fig. 7.
Multi-Drive Sunroof (A14102) Front of sunroof. See Fig. 24.
Multiple Restraint System Control Unit (A12) Rear of center console. See Fig. 6.
Navigation System (A112a) Left side of rear compartment. See Fig. 8.
Park Distance Control (PDC) (A81a) Right side of rear compartment. See Fig. 10.
Passenger's Seat Heating Module (A186a) Under front passenger seat. See Fig. 13.
Tire Pressure Control (RDC) (A85a) Right side of rear compartment. See Fig. 11.
Trailer Module (A6) Right side of rear compartment. See Fig. 10.
Transfer Box Control Module (A70006) Under carpet, on right side footwell. See Fig. 26.
Video Module (A197) Left side of rear compartment. See Fig. 8.
MOTORS
MOTORS LOCATION
Component Location
Air Distribution Flap Motor (M150) Center of dash, above radio. See Fig. 50.
Auxiliary Water Pump (M37) Left rear of engine compartment. See Fig. 40.
Blower Motor (M30) Behind right side of dash. See Fig. 38.
Defroster Flap Motor (M35) Behind right side of dash. See Fig. 39.
Driver's Door System Lock (S47) Left front door. See Fig. 36.
Driver's Rear Side Power Window Motor (M20b) Left rear door. See Fig. 33.
Driver's Rear Side System Lock (M15a) Left rear door. See Fig. 33.
Driver's Seat Angle Adjustment Drive (M218) Under driver seat. See Fig. 56.
Driver's Seat Forward/Backward Adjustment Drive Unit
Under driver seat. See Fig. 57.
(M216)
Driver's Seat Height Adjustment Drive Unit (M214) Under driver seat. See Fig. 56.
Driver's Seat Vacuum Pump (M55b) Right side of driver seat back. See Fig. 42.
Driver's Side Backrest Angle Adjustment Motor (M184) Under driver seat. See Fig. 55.
Driver's Window Motor (M21) Left front door. See Fig. 36.
E Box Fan (M6506) Near engine.
Electric Coolant Pump (M6035) (N52 & N51) Rear of engine. See Fig. 62.
Electric Coolant Pump (M6035) (N54) Rear of engine. See Fig. 63.
Electric Fan (M9) Front of engine compartment. See Fig. 34.
2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi
Electric Fuel Pump (M2) Under right rear seat. See Fig. 29.
Electric Steering Column Adjustment (M137a) Behind steering wheel. See Fig. 49.
Footwell Flap Motor (M31) Center of dash, above radio. See Fig. 53.
Fresh Air/Recirculating Air Flap Motor (M111) Behind right side of dash. See Fig. 38.
Front Mixing Flap Motor (M4729) Left side of dash. See Fig. 61.
Glass Roof Motor (M14105) Front center of roof. See Fig. 67.
Headlight Washer Pump (M7) Behind right front wheel. See Fig. 31.
Left Mixed Air Flap Motor (M153) Center of dash, above radio. See Fig. 52.
Left Roller-Cover Lock (M300) Left side of rear compartment. See Fig. 58.
Left Seat Belt Positioner Motor (M49) Left rear side interior panel. See Fig. 41.
Metering Pump (M180) Under vehicle. See Fig. 54.
Mixer Flap Motor (M152) Center of dash, above radio. See Fig. 51.
Passenger's Backrest Angle Adjustment Drive (M58a) Under passenger seat, on track. See Fig. 44.
Passenger's Door System Lock (S49) Right front door. See Fig. 37.
Passenger's Rear Side Power Window Motor (M22b) Right rear door. See Fig. 35.
Passenger's Rear Side System Lock (M14a) Right rear door. See Fig. 35.
Passenger's Seat Angle Adjustment Drive (M61a) Under passenger seat. See Fig. 45.
Passenger's Seat Forward/Backward Adjustment Drive
Under passenger seat. See Fig. 45.
(M60a)
Passenger's Seat Height Adjustment Drive (M59a) Under passenger seat, on track. See Fig. 45.
Passenger's Seat Vacuum Pump (M56b) Left side of passenger seat back. See Fig. 43.
Passenger's Window Motor (M23) Right front door. See Fig. 37.
Rear Compartment Mixing Flap Motor (M4723) Under right side of dash. See Fig. 60.
Rear Window Lock (M96a) Rear compartment door. See Fig. 48.
Behind rear seats, center of rear window. See
Rear Window Roller Sun Blind Motor (M74)
Fig. 47.
Rear Window Washer Pump (M95) Behind right front wheel. See Fig. 31.
Right Mixed Air Flap Motor (M154) Center of dash, above radio. See Fig. 53.
Right Roller-Cover Lock (M301) Right side of rear compartment. See Fig. 59.
Right Seat Belt Positioner Motor (M62) Right rear side interior panel. See Fig. 46.
Starter (M6510a) Near bottom of engine.
Towing Hitch Release Drive Unit (M8540) Rear of vehicle.
Trunk Lid Central Locking Drive (M17a) On rear compartment door. See Fig. 32.
Variable Valve Timing Gear Actuator (M6353) Right side of engine. See Fig. 64.
Visor Motor (M14104) Front of roof. See Fig. 66.
VTG Actuator (M8533) Under vehicle. See Fig. 65.
Windshield Washer Pump (M4) Behind right front wheel. See Fig. 31.
Wiper Motor (M3a) Left side of windshield. See Fig. 30.
SENDING UNITS & SENSORS

SENDING UNITS & SENSORS LOCATION
2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi
Component Location
Air Mass Flow Sensor (B6207b) Left side of engine. See Fig. 99.
Right rear of engine compartment. See Fig.
Automatic Air Recirculation Sensor (B414)
88.
Battery Sensor (B895) Right side of rear compartment. See Fig. 90.
Boost Pressure Sensor (B2014) Left side of engine. See Fig. 93.
Camshaft Sensor - Exhaust (B6224) Front of engine. See Fig. 100.
Camshaft Sensor - Intake (B6214) Front of engine. See Fig. 100.
Characteristic Map Thermostat (Y6279) (N51 & N52) Rear of engine. See Fig. 62.
Characteristic Map Thermostat (Y6279) (N54) Rear of engine. See Fig. 63.
Charge Air Temperature Sensor (B2012a) Left front side of generator. See Fig. 92.
Condensation Sensor (B100) Center of windshield. See Fig. 83.
Right front of engine compartment. See Fig.
Coolant Pressure Sensor (B8)
72.
Crankshaft Position/RPM Sensor (B6203) Top of engine. See Fig. 97.
Double Knock Sensor (B62400) Left side of engine. See Fig. 96.
DSC Sensor (B9801) Left front footwell. See Fig. 102.
Eccentric Shaft Sensor (B60213) Top of engine. See Fig. 104.
Engine Coolant Temperature Sensor (B6236a) Rear of engine. See Fig. 62.
Evaporator Temperature Sensor (B14b) Center of dash. See Fig. 53.
Footwell Temperature Sensor (B109a) Center of dash. See Fig. 51.
Front Left Wheel Speed Sensor (B2) Front of left front wheel. See Fig. 69.
Front Ride Height Sensor (B42b) Behind left front wheel. See Fig. 77.
Front Right Wheel Speed Sensor (B1) Front of right front wheel. See Fig. 68.
Fuel Temperature Sensor (B2292) Left side of engine. See Fig. 94.
Intake Pipe Pressure Sensor (B6239) Top left side of engine. See Fig. 101.
Left "B" Pillar Airbag Sensor (A173) (Coupe) Left rear side of interior panel. See Fig. 141.
Left "B" Pillar Airbag Sensor (A173) (Except Coupe) Left middle interior panel. See Fig. 142.
Left side of engine compartment. See Fig.
Left Front Airbag Sensor (B10508a)
103.
Left Front Brake Pad Wear Sensor (B16a) Behind left front wheel. See Fig. 73.
Left Front Door Airbag Sensor (B78a) Front of left front door. See Fig. 86.
Left Rear Wheel Speed Sensor (B4) Behind left rear wheel. See Fig. 71.
Left Tank Half Fuel Level Sensor (B25a) Under left rear seat. See Fig. 76.
Low Pressure Fuel Sensor (B6125a) Left side of engine. See Fig. 96.
Rear of engine, near transmission. See Fig.
Oil Condition Sensor (B62540)
107.
Outside Temperature Sensor (B21a) Front center of bumper. See Fig. 75.
Oxygen Sensor 1 Before Catalytic (B62101a) (N51 & On exhaust pipe, before catalytic. See Fig.
N52) 105.
Oxygen Sensor 1 Before Catalytic (B62101) (N54) Right side of engine. See Fig. 106.
Oxygen Sensor 1 Behind Catalytic (B62102a) (N51 &
2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi
N52) Right rear of engine. See Fig. 105.

Oxygen Sensor 2 Before Catalytic (B62201a) (N51 &
Right rear of engine. See Fig. 105.
N52)
Oxygen Sensor 2 Before Catalytic (B62201) (N54) Right side of engine. See Fig. 106.
Oxygen Sensor 2 Behind Catalytic (B62202a) (N51 &
Right rear of engine. See Fig. 105.
N52)
Radiator Outlet Temperature Sensor (B604b) Right side of engine. See Fig. 89.
Rail Pressure Sensor (B2261) Left side of engine. See Fig. 95.
Rain/Headlight Sensor (B57b) Center of windshield. See Fig. 83.
Rear Ride Height Sensor (B64a) Front of right rear wheel. See Fig. 84.
Right "B" Pillar Airbag Sensor (A174) (Coupe) Right rear side of interior panel. See Fig. 143.
Right "B" Pillar Airbag Sensor (A174) (Except Coupe) Right middle interior panel. See Fig. 144.
Right side of engine compartment. See Fig.
Right Front Airbag Sensor (B10509a)
98.
Right Front Door Airbag Sensor (B79) Rear of right front door. See Fig. 87.
Right Rear Brake Pad Wear Sensor (B17a) Front of right rear wheel. See Fig. 74.
Right Rear Wheel Speed Sensor (B3) Behind right rear wheel. See Fig. 70.
Right side of engine compartment. See Fig.
Secondary Air-Hot Film Air Mass Meter (B6206)
98.
Solar Sensor (B66) Top center of dash. See Fig. 85.
Steering Torque Sensor (I01096) Under vehicle. See Fig. 140.
Ventilation Temperature Sensor (B62) Center of dash. See Fig. 50.
SOLENOIDS & SOLENOID VALVES

SOLENOIDS & SOLENOID VALVES LOCATION
Component Location
DISA Controller 1 (Y6540) Top left of engine. See Fig. 101.
DISA Controller 2 (Y6541) Top left of engine. See Fig. 101.
Driver Backrest-Width Adjustment Valve Block (Y206) Right side of driver seat back. See Fig. 42.
Driver Lumbar Support Valve Block (Y193) Left side of driver seat back. See Fig. 42.
ECO Valve (Y14040a) Under starter. See Fig. 116.
Electric Throttle Valve (Y6390) Left side of engine. See Fig. 112.
Evaporator Emission Valve (Y6120) (N51 & N52) Left side of engine. See Fig. 112.
Evaporator Emission Valve (Y6120) (N54) Left rear side of engine. See Fig. 113.
Exhaust Flap (Y198) Left side of rear compartment. See Fig. 109.
Fuel Injector 1 (Y6101) (N51 & N52) Top of engine. See Fig. 110.
Fuel Injector 1 (Y6101) (N54) Top of engine. See Fig. 111.
2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi
Passenger's Backrest-Width Adjustment Valve Block
Left side of passenger seat back. See Fig. 43.
(Y0206)
Right side of passenger seat back. See Fig.
Passenger's Lumbar Support Valve Block (Y0206)
43.
Rail Pressure Control Valve (B2262) Left side of engine. See Fig. 93.
Left side of engine compartment. See Fig.
Suction Jet Pump Valve (Y6165a)
114.
VANOS Solenoid Valve - Exhaust (Y6276) Front of engine. See Fig. 100.
VANOS Solenoid Valve - Intake (Y6275) Front of engine. See Fig. 100.
Wastegate Valve 1 (Y6039) Right side of engine. See Fig. 106.
Wastegate Valve 2 (Y6723) Right side of engine. See Fig. 106.
Left side of auxiliary water pump. See Fig.
Water Valve (Y4)
40.
SWITCHES
SWITCHES LOCATION
Component Location
Air Distribution Microswitch (Y715) Center of dash. See Fig. 50.
Back-Up Light Switch (S8511) Rear of transmission. See Fig. 124.
Brake Fluid Level Switch (B18a) Left rear of engine compartment. See Fig. 9.
Brake Light Switch (S29) Under left side of dash. See Fig. 117.
Clutch Switch Module (S805a) Under left side of dash. See Fig. 123.
Coolant Level Switch (S63b) Right side of engine compartment. See Fig. 119.
Headlight Washer Relay (K6) Under right side of dash. See Fig. 2.
Hood Contact Switch (S19a) Left rear of engine compartment. See Fig. 9.
Oil Pressure Switch (B6231) (N51 & N52) Left side of engine compartment. See Fig. 91.
Oil Pressure Switch (B6231) (N54) Left rear side of engine. See Fig. 95.
Parking Brake Warning Switch (S31a) Under center console. See Fig. 118.
Park/Neutral Position Switch (Y19) Under shifter, in center console. See Fig. 108.
Passenger Airbag Deactivation Switch (S559) Right end of dash, near right front door. See Fig. 122.
Selector Lever Position Switch (S227) Under shifter, in center console. See Fig. 108.
Steptronic Switch (S224) Under shifter, in center console. See Fig. 108.
Washer Fluid Level Switch (S136a) Behind right front wheel. See Fig. 31.
MISCELLANEOUS
2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi
MISCELLANEOUS LOCATION
Component Location
AF Interference Suppressor Filter (U410) Left side of rear window panel. See Fig. 149.
Amplifier (A18) Left side of rear compartment. See Fig. 8.
Bluetooth Antenna (W18) Under left side of dash. See Fig. 152.
CD Changer (N22) Left side of rear compartment. See Fig. 8.
Classification Resistor (R8554) Under vehicle. See Fig. 65.
Compensator (N27a) Left side of rear compartment. See Fig. 145.
Crankshaft Breather Heating 1 (E65390) Left side of engine. See Fig. 101.
Digital Tuner (N48) Left side of rear compartment. See Fig. 147.
Driver Seat Belt Positioner Controller (I01157) Left rear side of interior panel. See Fig. 141.
Driver Side Airbag Inflator Assembly (G14b) Left side of driver seat back. See Fig. 133.
Driver's Seat Backrest Heating (E56a) In driver seat back. See Fig. 130.
Driver's Seat Belt Tensioner Generator (G12) Part of seat belt buckle assembly. See Fig. 132.
Driver's Seat Cushion Heating (E57a) In driver seat cushion. See Fig. 130.
Electric Auxiliary Heater (R6138) Center of dash. See Fig. 51.
Electric Lock (Y14035) Under vehicle. See Fig. 115.
Emergency Antenna (W19) Left rear side of interior panel. See Fig. 153.
Front Passenger Seat Belt Positioner Controller (I01158) Right rear side of interior panel. See Fig. 143.
Generator (G6524) Left front side of engine. See Fig. 92.
Ignition Coil 1 (T6151) (N51 & N52) Top of engine. See Fig. 126.
Ignition Coil 1 (Y6151) (N54) Top of engine. See Fig. 127.
Inner Antenna (W13a) Center of rear compartment. See Fig. 151.
Interior Antenna (W10) Rear of center console. See Fig. 150.
Jump Start Terminal Point (G6430) Right side of engine compartment. See Fig. 138.
Left Front RDC Transmitter (B43a) Front of left front wheel. See Fig. 78.
Left Head Airbag Inflator Assembly (G17) Left headliner. See Fig. 135.
Left Horn (H2a) Left side of front bumper. See Fig. 139.
Left Rear RDC Transmitter (B45a) Behind left rear wheel. See Fig. 80.
Left Rear Seat Belt Tensioner (G27) Under left rear seat. See Fig. 137.
OBDII Socket (X19527) Under left side of dash. See Fig. 120.
2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi
Passenger's Airbag Inflator Assemblies (G6) Top right side of dash. See Fig. 131.
Passenger Side Airbag Inflator Assembly (G15b) Right side of passenger seat back. See Fig. 134.
Passenger's Seat Backrest Heating (E59a) In passenger seat back. See Fig. 130.
Passenger's Seat Belt Tensioner Generator (G13) Part of seat belt buckle assembly. See Fig. 132.
Passenger's Seat Cushion Heating (E59a) In passenger seat cushion. See Fig. 130.
RDC Antenna (B46a) Under vehicle. See Fig. 82.
Rear Window Defroster (Ground) Lockout Circuit (Z2) Left side of rear window panel. See Fig. 149.
Rear Window Defroster (Positive) Lockout Circuit (Z1) Right side of rear window panel. See Fig. 154.
Right Front RDC Transmitter (B47a) Front of right front wheel. See Fig. 81.
Right Head Airbag Inflator Assembly (G18) Right headliner. See Fig. 136.
Right Horn (H3a) Right side of front bumper. See Fig. 75.
Right Rear RDC Transmitter (B44a) Behind right rear wheel. See Fig. 79.
Right Rear Seat Belt Tensioner (G28) Under right rear seat. See Fig. 137.
Satellite Receiver (N47) Left side of rear compartment. See Fig. 146.
Suppression Capacitor (I01046) Top of engine. See Fig. 127.
Telephone Transceiver (U400a) Center of rear compartment. See Fig. 148.
CONNECTORS
CONNECTORS LOCATION
Component Location
X181 Under right side of dash. See Fig. 159.
X273 Right middle interior panel. See Fig. 142.
X274 Right rear interior panel. See Fig. 143.
X384 Left side of rear compartment. See Fig. 121.
X623 Left front door. See Fig. 36.
X624 Right front door. See Fig. 37.
X691 Under left rear seat. See Fig. 76.
X782 Top right side of dash. See Fig. 131.
X1362 Under left side of dash. See Fig. 12.
X01504 Right side of driver seat back. See Fig. 157.
X1770 Right side of rear compartment. See Fig. 5.
X3507 Right rear side of interior panel. See Fig. 21.
X6400 Right side of engine compartment. See Fig. 138.
2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi

X10151 Under left rear seat. See Fig. 76.
X10321 Left rear door. See Fig. 33.
X10323 Left front door. See Fig. 36.
X10324 Right front door. See Fig. 37.
X11609 Left rear side of interior panel. See Fig. 41.
X18264 Right side of rear window panel. See Fig. 154.
X018316 Right side of driver seat back. See Fig. 157.
X60552 Right rear of engine compartment. See Fig. 17.
GROUNDS
GROUNDS LOCATION
Component Location
X165 Left side of engine compartment. See Fig. 103.
X166 Right side of engine compartment. See Fig. 98.
X170 Left side of engine compartment. See Fig. 40.
X273 Right middle interior panel. See Fig. 167.
X1441 Under center console. See Fig. 6.
X6170 Top of engine. See Fig. 168.
X6176 Right side of engine. See Fig. 126.
X6177 Right side of engine. See Fig. 126.
X6454 Right rear of engine compartment. See Fig. 169.
2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi
X6455 (N51 & N52) Right side of engine coolant pump. See Fig. 62.
X6455 (N54) Right side of engine coolant pump. See Fig. 63.
X13016 Left rear side of interior panel. See Fig. 153.
SPLICES
SPLICES LOCATION
Component Location
X1019 Right side of dash. See Fig. 166.
X01142 Center of dash. See Fig. 155.
X01362 Left side of center console. See Fig. 156.
X10808 Right side of center dash. See Fig. 163.
X10809 Right side of center dash. See Fig. 163.
X13722 Under left of dash. See Fig. 164.
X13723 Under left of dash. See Fig. 164.
X13724 Behind left front wheel. See Fig. 165.
X13725 Behind left front wheel. See Fig. 165.
COMPONENT LOCATION GRAPHICS
NOTE: Figures may show multiple component locations. Refer to appropriate table for
proper figure references.
2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi
Fig. 1: Right Side Of Dash


2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi
Fig. 3: Right Rear Of Engine Compartment


Fig. 5: Right Side Of Rear Compartment

2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi
Fig. 6: Under Center Console

Fig. 7: Left Front Bumper

Fig. 8: Left Side Of Rear Compartment

2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi
Fig. 9: Left Rear Of Engine Compartment



2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi
Fig. 12: Left Side Of Dash

Fig. 13: Under Passenger Seat

Fig. 14: Under Driver Seat

2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi



2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi
Fig. 18: Behind Left Front Wheel Housing



2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi
Fig. 21: Right Side Of Right Rear Seat

Fig. 22: Center Of Dash

2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi
Fig. 23: Part Of Accelerator Pedal

Fig. 24: Center Of Roof, Forward Of Sunroof

2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi
Fig. 25: Under Vehicle, Near Right Front Wheel

Fig. 26: Under Carpet, Front Of Passenger Seat


2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi
Fig. 28: Right Front Bumper

Fig. 29: Under Right Rear Seat

Fig. 30: Left Side Of Windshield

2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi
Fig. 31: Behind Right Front Wheel Housing

Fig. 32: Rear Compartment

Fig. 33: Left Rear Door

2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi
Fig. 34: Front Of Engine

Fig. 35: Right Rear Door

2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi
Fig. 36: Driver Door

Fig. 37: Front Passenger Door

2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi


2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi
Fig. 40: Left Side Of Engine Compartment

Fig. 41: Left Side Of Left Rear Seat

Fig. 42: On Driver Seat Back

2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi
Fig. 43: On Passenger Seat Back



2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi
Fig. 46: Right Side Of Right Rear Seat

Fig. 47: Center Of Rear Window

Fig. 48: Rear Window

2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi



2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi


Fig. 54: Under Vehicle

2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi



2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi
Fig. 58: Left Roller Cover

Fig. 59: Right Roller Cover


2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi

Fig. 62: Engine Cooling System

Fig. 63: Engine Cooling System

2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi
Fig. 64: Right Side Of Engine


Fig. 66: Center Of Roof, Forward Of Sunroof

2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi
Fig. 67: Right Side Of Headliner

Fig. 68: Front Of Right Front Wheel

2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi
Fig. 69: Front Of Left Front Wheel

Fig. 70: Right Rear Wheel Sensor

2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi
Fig. 71: Left Rear Wheel Sensor

Fig. 72: Right Front Of Engine Compartment

2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi
Fig. 73: Left Rear Of Wheel Housing

Fig. 74: Brake Wear Sensor

2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi
Fig. 75: Right Front Of Bumper

Fig. 76: Under Left Rear Seat

2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi
Fig. 77: Rear Of Left Front Wheel

Fig. 78: Front Of Left Front Wheel

2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi
Fig. 79: Rear Of Right Rear Wheel

Fig. 80: Rear Of Left Rear Wheel

2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi
Fig. 81: Front Of Right Front Wheel


2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi
Fig. 83: Top Center Of Windshield

Fig. 84: Front Of Right Rear Wheel

2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi
Fig. 85: Top Center Of Dash

Fig. 86: Driver Door

2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi
Fig. 87: Front Passenger Door


2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi
Fig. 89: Right Side Of Engine Compartment


2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi

Fig. 92: Generator


2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi

Fig. 95: Left Side Of Engine

Fig. 96: Knock Sensor

2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi
Fig. 97: Crankshaft Sensor

Fig. 98: Right Side Of Engine

2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi
Fig. 99: Air Mass Flow Sensor

Fig. 100: Front Of Engine

2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi
Fig. 101: Top Of Engine

Fig. 102: Front Of Driver Seat


2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi

Fig. 105: Oxygen Sensor

Fig. 106: Oxygen Sensor

2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi
Fig. 107: Oil Pressure Sensor

Fig. 108: Center Console

2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi

Fig. 110: Fuel Injectors


2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi

Fig. 113: Rear Of Engine

2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi


2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi


2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi


2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi

Fig. 121: Rear Compartment


2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi


2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi



2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi


Fig. 130: Heated Seat Elements

2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi
Fig. 131: Top Right Of Dash

Fig. 132: Seat Belt Buckle Assembly

2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi


Fig. 135: In Headliner

2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi
Fig. 136: In Headliner

Fig. 137: Under Rear Seat

2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi

Fig. 139: Left Side Of Front Bumper


2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi
Fig. 141: Left Rear Interior Panel

Fig. 142: Left Middle Interior Panel

Fig. 143: Right Rear Interior Panel

2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi
Fig. 144: Right Middle Interior Panel


2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi


2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi
Fig. 148: Center Of Rear Compartment

Fig. 149: Left Side Of Rear Window Panel

2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi

Fig. 151: Center Of Rear Compartment

2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi
Fig. 152: Under Left Side Of Dash

Fig. 153: Left Rear Interior Panel

2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi
Fig. 154: Right Side Of Rear Window Panel



2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi
Fig. 157: Driver Seat Back



2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi



2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi


Fig. 165: Behind Left Front Wheel

2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi

Fig. 167: Right Middle Interior Panel


2007 BMW 335i
2007 BMW 328i, 328xi, 335i & 335xi

2007 BMW 335i
ACCESSORIES AND EQUIPMENT Electrical drives - Repair Instructions
Electrical drives - Repair Instructions
GENERAL SAFETY INFORMATION


CENTRAL LOCKING UNIT/UNLOCKING

67 11 510 REMOVING AND INSTALLING/REPLACING SERVODRIVE FOR FRONT LEFT OR
RIGHT DOOR LOCKING MECHANISM
NOTE: Servodrive for door locking mechanism is integrated in door lock in front door.
Procedure is described in Door Lock In Front Door... .
67 11 555 REMOVING AND INSTALLING / REPLACING SERVODRIVE FOR TANK FILLER FLAP
(COUPE)
 Remove Top Trim From Tail Panel

 Partially remove Luggage Compartment Wheel Arch Trim On Right
Feed out emergency actuation pull strap (1) in direction of arrow.
Fold acoustic insulation (2) forwards.

2007 BMW 335i
Fig. 1: Identifying Strap, Strap Removal Direction And Acoustic Insulation

Slacken screws (2)
Feed servodrive for fuel filler flap (3) in direction of arrow out of retaining plate (4) and remove.
Installation:
Carry out adjustment of servodrive for tank filler flap (3) via both elongated holes. It must be possible to lock or
unlock the fuel filler flap completely.
Fig. 2: Identifying Plug Connection, Screws, Retaining Plate And Fuel Filler Flap
Turn sleeve (1) with a suitable tool (e.g.: pointed pliers) approx. 45° in direction of arrow and pull out of cover
housing (2).
Fig. 3: Identifying Cover Housing, Sleeve And Removal Direction

2007 BMW 335i
Installation:
Slide sleeve (1) over locking pin (2).
Make sure sleeve (1) is correctly engaged in cover housing (3).
Fig. 4: Identifying Cover Housing, Sleeve And Locking Pin

Replacement:
Release screws (1).
Disengage emergency actuation pull strap (2) from retainer (5) and remove towards front.
If necessary, unclip locking pin (3) in direction of arrow from servodrive for tank filler flap (4).
Fig. 5: Identifying Locking Pin, Screws, Strap, Retainer And Filler Flap
67 11 555 REMOVING AND INSTALLING/REPLACING SERVODRIVE FOR TANK FILLER FLAP

(CONVERTIBLE)
2007 BMW 335i
 Remove RIGHT LUGGAGE COMPARTMENT WHEEL ARCH TRIM .

 Lay sound insulation in working area to one side
Slacken screws (1).
Feed out servodrive (2) with emergency actuator pull strap (3).
Fig. 6: Identifying Emergency Actuator Pull Strap, Servodrive, And Screws

Turn sleeve (1) with a suitable tool (e.g.: pointed pliers) approx. 45° in direction of arrow and pull out of cover
housing (2).
Fig. 7: Pulling Sleeve Out Of Cover Housing

Installation:
2007 BMW 335i
Slide sleeve (1) over locking pin (2).
Make sure sleeve (1) is correctly engaged in cover housing (3).
Fig. 8: Sliding Sleeve

Replacement:
Release screws (1).
Disengage emergency actuation pull strap (2) from retainer (5) and remove towards front.
If necessary, unclip locking pin (3) in direction of arrow from servodrive for tank filler flap (4).
Fig. 9: Pulling Strap From Retainer

67 11 560 REPLACING SERVODRIVE FOR REAR LID LOCK

2007 BMW 335i
This operation is described under:
Removing Rear Lid Lock
67 11 590 REMOVING AND INSTALLING/REPLACING ACTUATOR DRIVE FOR GLOVE BOX

LOCKING MECHANISM (CONVERTIBLE)
NOTE: For purposes of clarity, picture shows glove box removed.
Open glovebox.
Release locks.
Remove cover (1).

Remove circlip from damper (1).
Detach damper (1) from glove box flap (2).

2007 BMW 335i
Fig. 11: Identifying Glove Box Flap, Damper, And Circlip For Damper
Reach through the opening that was exposed during the first work step and detach the stop pad (1) in the
direction of the arrow from the glove box (2).
Fig. 12: Detaching Stop Pad From Glove Box

Detach flap (1) from glove box (2) as shown.

2007 BMW 335i
Fig. 13: Identifying Glove Box And Flap

Unclip the cover inside (1) with a suitable tool (2).
Fig. 14: Unclipping Cover Inside Using Suitable Tool

Press the locks to the inside at the marked points and secure with suitable tool at point (1).
2007 BMW 335i
Fig. 15: Pressing Locks To Inside At Marked Points And Securing With Suitable Tool
Example: Securing with pop rivet (1).
Release screws at marked points.
Detach lock unit (2) from glove box flap (3).
Fig. 16: Detaching Lock Unit From Glove Box Flap

Release plug connection (1) at actuator drive (2) and disconnect.
Remove lock unit with actuator drive (2).

2007 BMW 335i
Fig. 17: Identifying Actuator Drive And Connector

Removed lock unit with actuator drive (1).
Fig. 18: Identifying Removed Lock Unit With Actuator Drive

67 11 610 REMOVING AND INSTALLING/REPLACING SERVODRIVE IN STORAGE

COMPARTMENT (CONVERTIBLE)
 Remove STORAGE COMPARTMENT .
Release screws (1).
Lever out air duct (3) at catch (2) and feed out of storage compartment.
2007 BMW 335i
Fig. 19: Identifying Air Duct And Catch

First feed air duct (1) to right out of guides (2) and duct (3), then remove to left out of storage compartment.
Installation:
Fig. 20: Identifying Air Duct, Guide And Duct

Unclip Bowden cable (1) from holder (2).
Release screws (3).
Remove servodrive (4).

2007 BMW 335i
Fig. 21: Identifying Bowden Cable, Holder, Servodrive, And Screws

MIRROR ADJUSTMENT
67 13 001 REPLACING DRIVE UNIT FOR ELECTRICALLY OPERATED LEFT OR RIGHT DOOR
MIRROR
 Remove Mirror Glass for mirror
Release screw (1).
Remove drive for electrically operated door mirror (2) in direction of arrow from mirror housing (3).
Fig. 22: Identifying Door Mirror, Mirror Housing And Screw

Installation:
2007 BMW 335i
Fit drive for electrically operated door mirror (1) so that pin housing (2) engages exactly in plug housing (3) and
locators (4) slide into guides (5).
Fig. 23: Identifying Electrically Operated Door Mirror, Pin Housing, Plug Housing, Locators And Guide
67 13 025 REPLACING MIRROR ELECTRONICS FOR ELECTRICALLY OPERATED LEFT OR

RIGHT DOOR MIRROR
 Remove DRIVE FOR DOOR MIRROR

 Remove HOUSING ON DOOR MIRROR
 Remove DOOR MIRROR
Release screw (1).
Remove cover cap (2).

2007 BMW 335i
Fig. 24: Identifying Screw And Cover Cap

Press together catches (1) of plug (2) and press plug (2) through in outward direction.
Unlock plug (2) on contact carrier (3) and pull out.
Fig. 25: Identifying Catches, Plug And Contact Carrier

Carefully release latch mechanisms (1).
Feed out mirror electronics (2) with cable.

2007 BMW 335i
Fig. 26: Identifying Latch Mechanisms And Mirror Electronics

SERVO-POSITIONING DRIVES
67 16 011 REMOVING AND INSTALLING/REPLACING LEFT VERTICAL AIM ADJUSTER
(XENON HEADLIGHT)
WARNING: Version with xenon headlights: Danger to life due to high voltage!
Therefore disconnect all components from voltage supply before removal.
Work on the entire xenon lighting system (control unit, ignition unit with
lamp) may only be carried out by specialist personnel.
 Remove Wheel Arch Cover Front Section at front
NOTE: For purposes of clarity, following illustrations show headlight removed.

2007 BMW 335i

Release screws (1).

Slide headlight insert (2) upwards in direction of arrow.
Move vertical aim adjuster (3) downwards in direction of arrow and feed out.
2007 BMW 335i
Fig. 29: Identifying Plug Connection, Headlight Insert And Vertical Aim Adjuster
Installation:
Feed ball head of vertical aim adjuster (1) into mounting (2).
Fig. 30: Identifying Vertical Aim Adjuster And Mounting

After installation:
 Adjust Headlights
67 16 016 REMOVING AND INSTALLING/REPLACING RIGHT HEADLIGHT VERTICAL AIM

ADJUSTER
Removing And Installing / Replacing Left Headlight Vertical Aim Adjuster
DRIVE, SEAT ADJUSTMENT

2007 BMW 335i
67 31... OVERVIEW OF DRIVE UNITS FOR SEAT ADJUSTMENT (CONVERTIBLE)
Fig. 31: Overview Of Drive Units For Seat Adjustment (Convertible)

67 31 531 REMOVING AND INSTALLING/REPLACING DRIVE UNIT FOR BACKREST ANGLE

ADJUSTMENT (COUPE)
 Remove OUTER COVER
Release screws (1).
Remove drive for backrest angle adjustment from flange.

2007 BMW 335i
Installation:
Make sure drive shaft is correctly seated in gearbox.
Fig. 32: Identifying Screws And Plug Connections

67 31 531 REMOVING AND INSTALLING/REPLACING DRIVE UNIT FOR BACKREST ANGLE

ADJUSTMENT (CONVERTIBLE)
 Partially remove BACKREST COVER
Release screws (1).
Remove drive unit (3) in direction of arrow from flange.
If necessary, pull out inner drive shaft from drive unit or gearing.
Installation:
Make sure drive shaft is correctly seated.
Make sure drive unit is correctly seated on flange.

2007 BMW 335i
Fig. 33: Identifying Drive Unit, Connector, And Screws

67 31 501 REMOVING AND INSTALLING/REPLACING FORWARD/BACK SEAT ADJUSTMENT

DRIVE UNIT (COUPE)
 Remove FRONT SEAT
Unfasten plug connections (1) and disconnect.
Press out pins of expanding rivets (2) and lever out expanding rivets.
Carefully bend long flex shaft with jacket tube and pull out of gearing.
Pull drive with short flex shaft out of gearing.
Fig. 34: Identifying Connectors And Expanding Rivets

2007 BMW 335i
Bend metal tab (1) open.
Installation note:
Slide seat rail with opening forwards or back until bushing for flex shaft mounting of worm gear is flush.
Insert flex shaft.
Fig. 35: Sliding Seat Rail

Installation note:
Slide short flex shaft (1) into longitudinal seat adjustment gearing square.
Bend long flex shaft (2) upwards and slide into longitudinal seat adjustment gearing.
Make sure flex shafts are correctly seated in transmissions.

2007 BMW 335i
Fig. 36: Identifying Short Flex Shaft And Long Flex Shaft
Installation note:
PTFE hoses (1) are shrink-fitted onto end pieces.
Check that hoses are free from damage.

2007 BMW 335i
Fig. 37: Identifying PTFE Hoses

67 31 501 REMOVING AND INSTALLING/REPLACING FORWARD/BACK SEAT ADJUSTMENT

DRIVE UNIT (CONVERTIBLE)
Release screws (1).

Release screws (1).
Unlock plug connections (2) and (3) and disconnect.

2007 BMW 335i
Pull short flex shaft including carrier plate out of gearing.
Feed out carrier plate with drive unit.
Fig. 39: Identifying Connectors And Screws

Installation note:
Slide short flex shaft (1) into longitudinal seat adjustment gearing square.
Bend long flex shaft (2) upwards and slide into longitudinal seat adjustment gearing.

2007 BMW 335i
Installation note:
PTFE hoses are shrink-fitted onto end pieces.

2007 BMW 335i

67 31 521 REMOVING AND INSTALLING/REPLACING DRIVE UNIT FOR SEAT HEIGHT

ADJUSTMENT (COUPE)
Remove drive unit for seat height adjustment.
Installation:

2007 BMW 335i
Fig. 42: Identifying Plug Connections And Screws

67 31 521 REMOVING AND INSTALLING/REPLACING DRIVE UNIT FOR SEAT HEIGHT

Release screws (1).
Installation:
Make drive shaft is correctly seated.

2007 BMW 335i
Fig. 43: Removing Drive Unit

Unlock and disconnect plug connections (1 and 2).

67 31 511 REMOVING AND INSTALLING/REPLACING DRIVE UNIT FOR SEAT TILT

ADJUSTMENT (COUPE)
Installation:
2007 BMW 335i
Fig. 45: Identifying Plug Connections And Screws

67 31 511 REMOVING AND INSTALLING/REPLACING DRIVE UNIT FOR SEAT TILT

Unclip holder (1) from plug housing.
Installation:
Make sure holder (1) for plug connection is correctly seated

2007 BMW 335i

Release screws (1).
Installation:
Fig. 47: Removing Drive Unit

Unlock and disconnect plug connections (1 and 2).

2007 BMW 335i
67 31 572 REMOVING AND INSTALLING/REPLACING DRIVE FOR HEAD RESTRAINT HEIGHT

ADJUSTMENT ON LEFT OR RIGHT FRONT SEAT (CONVERTIBLE)
 Remove REAR PANEL ON FRONT SEAT BACKREST
Remove drive unit from flange.
Installation:
Fig. 49: Identifying Connector And Screws

DRIVE, SLIDE-TILT SUNROOF

67 61 005 REPLACING DRIVE WITH GEAR (FRONT) FOR ACTUATING SLIDE/TILT SUNROOF
 Remove Roof Switch Cluster

2007 BMW 335i
NOTE: Secure drive with gear for actuating slide/tilt sunroof (3) against falling out.
Release screws (2), for tightening torque refer to 54 13 1AZ in 54 13 ELECTRIC SUN ROOF
COMPONENTS .
NOTE: Screws (2) are microencapsulated.
Remove drive with gear for actuating slide/tilt sunroof (3).
Fig. 50: Identifying Plug Connection, Screws And Slide/Tilt Sunroof Actuating Gear
Installation:
Insert gear wheel (1) of drive with gear for actuating slide/tilt sunroof (2) exactly in gear teeth (3).
Fig. 51: Identifying Gear Teeth, Sunroof And Gear Wheel

2007 BMW 335i
Installation:
 Initialize Slide/Tilt Sunroof
DRIVE, WINDOW REGULATOR

67 62... NOTES ON INITIALIZING POWER WINDOW UNIT IN FRONT DOOR (COUPE)
There is no anti-trapping protection during initialization.
Rear power window unit does not have one-touch control function or anti-
trapping protection and therefore does not require initialization.
Initialization is performed on the power window switch of the relevant door.
Requirements for correct initialization:
 Terminal "R" activated

 Convertible top, doors and windows closed
 Sufficient battery voltage; connect charger if necessary
Initialization comprises:
 Erasure of initialization
 Reinitialization
An initialization must be performed:
 In the event of malfunctions, e.g. no one-touch control function, no opening or if available no comfort
function is possible
 After the power window drive has been replaced
 After work is carried out on the power window mechanism
 If necessary, after a power supply interruption, e.g. disconnection of the battery or disconnection of the
power supply to the door
 After the door window glass has been removed and installed or replaced
 After adjustment work on the door window glass
 After adjustment work on the convertible top
 After replacement of seals
Erasure of initialization:
 Open door window glass fully

2007 BMW 335i
 Actuate power window switch in "Open" position (second switch position) and hold down for between 15
and 20 seconds
This erases initialization of the power window, anti-trapping protection and toll function are inactive.
Check whether one-touch control (toll) function is inactive, otherwise repeat procedure.
Reinitialization:
 Close door window completely

 Once the upper end position has been reached, hold power window switch in "Close" position (second
switch stage) for approx. 2 seconds longer
This completes initialization.
NOTE: Carry out function check (one-touch control function, anti-trapping protection
and, if necessary, comfort function).
67 62... NOTES ON INITIALIZING POWER WINDOW UNIT IN FRONT DOOR (CONVERTIBLE)

There is no anti-trapping protection during initialization.
An initialization must be performed:
 In the event of malfunctions, e.g. no one-touch control function, no opening or if available no comfort
function is possible
 After the power window drive has been replaced
 After work is carried out on the power window mechanism
 If necessary, after an open circuit, e.g. disconnection of the battery or disconnection of the power supply
to the door
 After the door window glass has been removed and installed or replaced
 After adjustment work on the door window glass
 After adjustment work on the convertible top
 After replacement of seals
Initialization is performed on the power window switch of the relevant door.
Requirements for correct initialization:
 Terminal "R" activated

 Doors and windows closed
 Sufficient battery voltage; connect charger if necessary
2007 BMW 335i
Initialization comprises:
 Erasure of initialization
 Reinitialization
Erasure of initialization:

 Actuate power window switch in "Open" position (second switch position) and hold down for between 15
and 20 seconds
This clears initialization of the power window. Anti-trapping protection and one-touch control (toll) function
are inactive.
Check whether one-touch control (toll) function is inactive, otherwise repeat procedure.
Reinitialization:

 After upper end position is reached, interrupt actuation of power window switch and then hold switch
again for approx. 1 second in "Close" position (second switch position)
again for approx. 1 second in "Open" position (second switch position)
again for approx. 1 second in "Close" position (second switch position)
This completes initialization.
NOTE: Carry out function check (one-touch control function, anti-trapping protection
and, if necessary, comfort function).
NOTE: The power window can also be initialized in the BMW diagnosis system by
means of a diagnosis job.
67 62 000 REMOVING AND INSTALLING OR REPLACING FLAT MOTOR FOR FRONT LEFT OR
RIGHT POWER WINDOW REGULATOR
 Detach SOUND INSULATION from front door in working area
Unlock and disconnect connector (1) from flat motor.

2007 BMW 335i
Fig. 52: Identifying Connector For Flat Motor

Release screws (1).
Remove flat motor (2) with cable housing.
Fig. 53: Identifying Flat Motor Screws

Release screws (1).
Remove flat motor.
Installation note:
Exactly place flat motor on power window regulator gearing.

2007 BMW 335i
Fig. 54: Removing Flat Motor

NOTE: Cable roll (1) must remain in cable housing (2).
Fig. 55: Identifying Cable Roll In Cable Housing

Replacement:
A normalization must be carried out in order to activate anti-trapping protection.
Operating sequence for normalization:
 Operate corresponding power window switch in "Close" setting.

 Once the upper end position has been reached, hold power window switch down for approx. 1 second
more.
Normalization is thus completed.

2007 BMW 335i
NOTE: Carry out function check (one-touch function, anti-trapping protection and, if
necessary, comfort function).
67 62 020 REMOVING AND INSTALLING/REPLACING FLAT MOTOR FOR REAR LEFT OR

RIGHT POWER WINDOW UNIT (CONVERTIBLE)
 Remove REAR POWER WINDOW UNIT .
Release screws (1), tightening torque: 3.5 Nm
Carefully turn power window unit (2) over.
Fig. 56: Identifying Power Window Unit And Screws

Remove flat motor (1) from power window unit (2).
Installation:
Fit flat motor (1) exactly on teeth of power window unit.

2007 BMW 335i
Fig. 57: Identifying Power Window Unit And Flat Motor

DRIVE, WIPER/HEADLIGHT WASHER SYSTEM

67 63 512 REPLACING WIPER MOTOR
Removing Complete Console For Windscreen Wiper System.
DRIVE, SEAT ADJUSTMENT

67 66 010 REMOVING AND INSTALLING/REPLACING LUMBAR SUPPORT DRIVE MECHANISM
ON FRONT SEAT, LEFT OR RIGHT
 Remove Rear Panel On Front Seat Backrest
Remove drive unit for lumbar support (2) with jacket from backrest frame and expose.
Installation:
Make sure drive unit for lumbar support (2) is in correct installation position.
2007 BMW 335i
Fig. 58: Identifying Lumbar Support And Plug Connection

Detach hose (1) from drive unit (2).
NOTE: Gently heat hose (1) if stuck.
Installation:
Hose (1) on drive unit (2) must not be kinked.
Pull jacket (3) off drive unit (2).
Remove drive unit for lumbar support (2).
Fig. 59: Identifying Hose, Drive Unit And Jacket

2007 BMW 335i
ENGINE Engine Electrical System - 335i, 335xi
ENGINE
Engine Electrical System - 335i, 335xi
00 TROUBLESHOOTING
12 00 ... INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY
Observe safety instructions for handling vehicle battery.
Before disconnecting battery:
Turn off the ignition and other electrical loads/consumers to prevent sparking when reconnecting.
NOTE: If the ignition is not turned off when the battery is disconnected, fault memories
may be set in some control units.
IMPORTANT:  There is a danger of mixing up battery leads: If the battery positive and
negative leads are the same color and you are in doubt, follow the polarity
to the battery, then mark and cover the leads.
 On vehicles with radio code: After disconnecting the battery, the radio
code must be re-entered. Therefore obtain the radio code card from the
customer beforehand. Note stored stations and restore them after
connecting the battery.
 Stored settings of the on-board computer and clock will also be lost.
 All available central keys must be recoded for cars with first generation
infrared transmitter locking systems.
General notes on disconnecting battery:
 Do not disconnect battery leads and leads from alternator and starter motor while engine is running.
 Cars with IBS on battery negative terminal:
Do not under any circumstances pull/lever off pole shoes by force.
Do not under any circumstances release socket-head cap screw of IBS.
 Detach terminal of battery negative lead from car battery and second battery if fitted. Cover battery
negative terminal(s) and secure.
 When work is carried out on the electrical system, faults may be caused in the fault memories of some
control units when the battery is connected.
After connecting battery:

2007 BMW 335i
IMPORTANT: After a power supply interruption some equipment is disabled and must be
reactivated.
Likewise, individual settings are lost and must be activated.
Example:
 Vehicles with build date from 03/2007:
Teach-in mid-position for power steering
 If necessary, activate sliding sunroof

 If necessary, carry out adjustment of active front steering
 If necessary, activate power windows
 If necessary, activate mirror with compass
Please refer to the Progman user documentation for further information on vehicle-specific activation.
Vehicles with a two-battery system
Starter and equipment batteries
A two-battery system has a starter battery circuit and an equipment battery circuit. A secondary control unit
monitors both battery circuits. Depending on the situation, the battery circuits are connected to or isolated from
the secondary control unit via an isolating relay.
Two AGM batteries, whose design and properties are described in AGM batteries, are used as a storage battery.
IMPORTANT: These batteries must not under any circumstances be charged with a voltage in
excess of 14.8 V. Rapid programs must not be used either.
Receiving/giving starting assistance via jump start terminal
The engine can be jump-started with an external voltage supply via the jump start terminal on the right side of
the engine compartment.
NOTE: The starter battery is isolated from the alternators when the engine hood/bonnet
is open.
Giving starting assistance via the jump start terminal is thus limited by the capacity of the starter battery when
the engine hood/bonnet is open.
Charging starter and equipment batteries via jump start terminal
The starter battery is charged as a matter of priority with a charger connected to the jump start terminal. The
2007 BMW 335i
voltage at the starter battery is the decisive factor in determining whether the equipment battery is also included
in the charging operation. The secondary control unit automatically detects a charging operation at a charging
voltage at the starter battery of > or = 13.5 V. The isolating relay is closed and thus the equipment battery is
connected in parallel. Both batteries are now charged.
Prerequisite:
 Terminal 61 inactive
 Terminal 15 inactive
If terminal 15 becomes "active" during the charging operation, the isolating relay is opened immediately and
again only the starter battery is charged.
NOTE: When the engine hood is open, the isolating relay is also opened in normal
operation when the engine is running.
A special mode can be set by means of diagnosis for workshop/garage

operation. The isolating relay is closed from terminal R in this operating mode.
This mode is automatically reset once a distance of 5 km has been driven.
Trickle charging
The increased closed-circuit current consumption can be compensated for via the jump-start connection point
with the aid of the "Acctiva easy" battery trickle charger (Service Information 2 03 05 205).
IMPORTANT: The cigarette lighter is isolated from the electrical system after terminal R
"OFF" on a timed basis (60 mins.), thereby interrupting charging of the
equipment battery via the cigarette lighter. This is prevented if the battery
master switch (on the right side of the luggage compartment behind the panel)
is turned on and off again twice within 2 seconds. (Cigarette light battery
charging function).
12 00 ... INSTRUCTIONS FOR REMOVING AND INSTALLING ELECTRONIC CONTROL UNITS
IMPORTANT:  Disconnecting the vehicle battery will cancel the fault memories of control
units. Consequently, before disconnecting the car's battery, always
interrogate the fault memories. Investigate stored faults and, once any
faults have been remedied, cancel the fault memory.
 Control unit plugs should only ever be connected and disconnected while
the ignition is turned off.
 The removal and installation of components, relays, fuses etc. can cause
faults to be stored in fault memories capable of self diagnosis. Always
interrogate the fault memories after completing work on the electrical
system.
 Investigate stored faults and, once any faults have been remedied, cancel
2007 BMW 335i
the fault memory.
12 IGNITION WIRES, SPARK

12 12 011 REPLACING ALL SPARK PLUGS (N53, N54)
 12 1 172
 12 1 220
 12 1 230. See ENGINE ELECTRICAL SYSTEM -- SPECIAL TOOLS -- TWIN TURBO .
Switch off ignition.
Remove ignition coils.
 12 1 172
 12 1 220
Unscrew spark plugs with special tool 12 1 220 and extension (1) with min. 8° bend.
Installation:
Screw down spark plugs with special tool 12 1 220, extension (1) with min. 8° bend and torque limiter 12 1 172.
If special tool 12 1 172 is not used, observe tightening torque 12 12 1AZ, see ENGINE ELECTRICAL
SYSTEM -- TORQUE SPECIFICATIONS -- TWIN TURBO .
Fig. 1: Identifying Special Tool (12 1 220, 12 1 172)

2007 BMW 335i
Attach new spark plug (1) to special tool 12 1 230.
Fig. 2: Identifying Special Tool (12 1 230) On Spark Plug

Screw spark plug with special tool 12 1 230 in to cylinder head plug thread as far as it will go.
Fig. 3: Identifying Special Tool (12 1 230) In To Cylinder Head

13 IGNITION COIL
12 13 CARRYING OUT ENGINE CLEANING (N54, N53, N43)
IMPORTANT: When cleaning the engine, it is absolutely essential to keep the ignition coil
covers fitted in order to protect the injectors.
12 13 NOTES ON CHECKING IGNITION SYSTEM
Troubleshooting
2007 BMW 335i
-> Fault in fuel injection system
-> Spark plug faults
-> Ignition coil faults
-> Further fault patterns with evaluation
-> Additional fault notes for troubleshooting
Oscillograms
-> Normal oscillogram
-> Oscillograms of ignition coils from different manufacturers
Check
-> Secondary signal for stationary ignition distribution
12 13 511 REPLACING SPARK PLUGS (N54, N53)
 Read out fault memory of DME control unit.

 Check stored fault messages
 Remove acoustic cover
Unlock plug retainer (1) of ignition coil (2) and disconnect plug.
Pull ignition coil (2) up and out.
This procedure is applicable to all ignition coils.

2007 BMW 335i
Fig. 4: Pulling Ignition Coil

Installation:
Check that rubber seal of ignition coil (1) is correctly seated.
Fig. 5: Identifying Ignition Coil

Installation:
Push plug (1) with plug retainer (2) open onto ignition coil.
Carefully close plug retainer (2) in direction of arrow.
The plug retainer must snap into place without great effort.
2007 BMW 335i
Fig. 6: Closing Plug Retainer In Direction

NOTE: Now clear the fault memory.
14 ELECTRONIC SWITCHING
12 14 521 REPLACING CRANKSHAFT PULSE GENERATOR (N54)
protection).
damage) .
 Read out fault memory of DME control unit

NOTE: Installation location of pulse generator for crankshaft is underneath starter

motor.
Preparatory tasks:
 Remove intake air manifold
Detach plug (1) from crankshaft pulse generator (2). Release screw.
2007 BMW 335i
Installation:
Tightening torque 12 14 2AZ, see ENGINE ELECTRICAL SYSTEM -- TORQUE SPECIFICATIONS --

TWIN TURBO .
Withdraw pulse generator (2) from crankcase.
Installation:
Fig. 7: Identifying Plug From Crankshaft Pulse Generator

Now clear the fault memory.
12 14 523 REPLACING PULSE GENERATOR ON INLET CAMSHAFT (N54)
protection).

 Remove fan cowl

2007 BMW 335i
Release screw.

TWIN TURBO .
Remove pulse generator (2).
Fig. 8: Locating Pulse Generator

12 14 524 REPLACING PULSE GENERATOR ON EXHAUST CAMSHAFT (N54)
protection).

 Remove fan cowl
Release screw.

TWIN TURBO .
Remove pulse generator (2).

2007 BMW 335i
Fig. 9: Identifying Pulse Generator

12 14 550 REPLACING CONTROL UNIT (DME)

 Remove microfilter housing
IMPORTANT: Follow instructions for removing and installing control units
protection).
Replacement:
 Carry out programming/coding

 Carry out injector quantity adjustment (description at end of instruction)
IMPORTANT: It is absolutely essential to read out the fault memory with the MoDiC or the
BMW DIS and to create a fault memory printout.
Unlock fasteners (1) from below and slide upwards approx. 10 mm.
2007 BMW 335i
Unlock locks (2) in direction of arrow.
Remove cover (3).
Fig. 10: Identifying Fasteners, Locks & Cover

Release grommet (2) from electronics box.
Installation:
Make sure grommet (2) is correctly seated in housing (water tightness).
Unlock control unit (3) and raise slightly.
Fig. 11: Identifying Control Unit

Unlock plugs (1) using slide in direction of arrow and remove.

2007 BMW 335i
Installation:
Replacement:
Note device identification number and coding.
Fig. 12: Identifying Plugs

Injector adjustment:
If the DME control unit has been replaced, it will also be necessary to carry out adjustment of the injectors!
Injector adjustment is carried out with the aid of so-called adjustment values.
The adjustment values are printed in two blocks of three digits on each injector.
The adjustment values must be stored in the new control unit!
Fig. 13: Identifying Three Digits On Each Injector

2007 BMW 335i
If injector adjustment is not carried out, the engine may run roughly or fail to start.
Read off the adjustment values and enter according to the installation location (cylinder) of the injectors:
 Connect DIS Tester

 Identify car
 Select "Function selection"
 Select "Service functions"
 Select "Engine electronics"
 Select "Adjustment programs"
 Select "Adjust injectors"
 Change "Test schedule"
 The adjustment value must be entered for each cylinder.
Fig. 14: Identifying Installation Location (Cylinder) Of Injectors

12 14 600 REMOVING/REPLACING KNOCK SENSORS (N54, N53)
 13 5 281
 13 5 282. See FUEL SUPPLY SYSTEM -- SPECIAL TOOLS -- TWIN TURBO .
 32 1 270. See STEERING AND WHEEL ALIGNMENT - SPECIAL TOOLS .
2007 BMW 335i
WARNING: Disconnect battery negative terminal (risk of fire due to short-circuiting

on removal).
Electric fuel pump starts up automatically each time door is opened!
Carry out installation work on fuel system only with coolant temperature
below 40°C.
IMPORTANT: Adhere to conditions of absolute cleanliness when working on the high-

pressure fuel system.
Introduced contaminants can cause malfunctions in the system!
 Do not allow any dirt particles or foreign bodies to get into the system.
 Remove all traces of dirt before removing pipes or individual components.
 Use only fluff-free cloths.
 Seal all fuel system openings with protective caps or plugs.
damage) .

Recycling:
Fuel escapes when fuel lines are detached.
Catch and dispose of escaping fuel.

2007 BMW 335i
Unlock and detach fuel line (2).
Fig. 15: Identifying Fuel Line & Plug

Seal fuel lines with special tools 13 5 281 and 13 5 282.

Unscrew nut (1).
Seal fuel line connection of high-pressure pump with a matching plug from special tool kit 32 1 270.
Release screw (2).
Installation:
 Replace aluminum screw.

2007 BMW 335i
Fig. 17: Identifying Fuel Line Connection

Seal feed line with matching plug from special tool kit 32 1 270.
Fig. 18: Identifying Special Tool Kit (32 1 270)


2007 BMW 335i
Fig. 19: Identifying Unlock Plug

Release screws on both knock sensors (1) and remove knock sensors (1).
Installation:
 Replace aluminum screws.

 Tightening torque 12 14 1AZ, see ENGINE ELECTRICAL SYSTEM -- TORQUE
SPECIFICATIONS -- TWIN TURBO .
Fig. 20: Locating Aluminum Screws

Installation:
Clean contact surface of knock sensors on engine block.

2007 BMW 335i
Fig. 21: Locating Surface Of Knock Sensors On Engine Block

Installation:
Pre-install feed line (3).
In so doing, tighten screw connection hand-tight only (it must still be possible to move the line at the holder).
IMPORTANT: Sequence of screw connection must be observed!
 Tighten nut (1). Tightening torque 13 53 6AZ. See FUEL SYSTEM -- TIGHTENING TORQUE --
TWIN TURBO .
 Tighten screw (2). Replace aluminum screw. Tightening torque 13 53 9AZ. See FUEL SYSTEM --
TIGHTENING TORQUE -- TWIN TURBO .
Fig. 22: Identifying Feed Line & Screw


2007 BMW 335i
12 14 650 REPLACING SUCTION PRESSURE SENSOR ON INTAKE AIR MANIFOLD (N54)

NOTE: The installation location of the suction pressure sensor is at the rear end of the
intake air manifold.
Preparatory tasks:
Release screws and pull suction pressure sensor (2) out of intake air housing.
Tightening torque 13 62 2AZ. See FUEL SYSTEM -- TIGHTENING TORQUE -- TWIN TURBO .
Fig. 23: Identifying Pressure Sensor

Installation:
Check sealing ring for damage, replace if necessary.
When installing, coat sealing ring with suitable antiseize agent.

2007 BMW 335i
Fig. 24: Locating Sealing Ring

12 14 651 REPLACING SUCTION PRESSURE SENSOR ON CHARGE-AIR DUCT (N54)

NOTE: The installation location of the suction pressure sensor is at the rear end of the
charge-air duct.
Preparatory tasks:
 Remove suction filter housing.
Release screws and pull suction pressure sensor (2) out of charge-air duct.
Tightening torque 13 62 2AZ. See FUEL SYSTEM -- TIGHTENING TORQUE -- TWIN TURBO .
2007 BMW 335i
Fig. 25: Identifying Pressure Sensor

Installation:
Check sealing ring for damage, replace if necessary.
When installing, coat sealing ring with suitable antiseize agent.
Fig. 26: Locating Sealing Ring

12 14 700 CODING CONTROL MODULE (DME/DDE)
Connect MoDiC or DIS/GT1 Tester.

2007 BMW 335i
Switch on ignition.
Select "Coding" program.
For subsequent procedure, follow instructions in MoDiC or DIS/GT1 Tester.
Carry out adjustment of following control units:
 EWS (electronic immobilizer)

 DME (Digital Motor Electronics) or
 DDE (Digital Diesel Electronics)
Refer to "Diagnosis and Coding" service information bulletins on subject of coding.
12 14 705 PROGRAMMING CONTROL UNIT (DME/DDE)
Connect MoDiC or DIS/GT1 Tester.
Switch on ignition.
Select "Programming".
For subsequent procedure, follow instructions in MoDiC or DIS/GT1 Tester.
Carry out adjustment of following control units:
 EWS (electronic immobilizer)

 DME (Digital Motor Electronics) or
 DDE (Digital Diesel Electronics)
Refer to "Diagnosis and Coding" service information bulletins on subject of programming.
61 14 ... REMOVING AND INSTALLING/REPLACING ENGINE COMPARTMENT B+ TERMINAL
 Remove electronics box
Open cap (1) and release nut underneath.
Tightening torque 61 12 4AZ. See 12 AUXILIARY CABLE .
Remove cable lug mounting from positive battery leads.

2007 BMW 335i
Fig. 27: Identifying Positive Battery Leads Cap

Remove cover (1).

Unscrew nuts (1).
Tightening torque 61 12 4AZ. See 12 AUXILIARY CABLE .
Remove positive leads.
Release lock (2).
Remove B+ terminal with frame (3).
Installation:
2007 BMW 335i
Frame (3) must snap correctly into B+ terminal.
Fig. 29: Identifying Positive Leads

31 ALTERNATOR WITH DRIVE

12 31 ... REPLACING ALTERNATOR BELT PULLEY
Remove and install alternator drive belt.
Depending on alternator type, grip shaft with:
 hexagon socket
 multi-tooth socket or
 Torx socket wrench
Release nut with special tool 12 7 110.
Installation:
Tightening torque, 12 31 2AZ/12 31 3AZ, see ENGINE ELECTRICAL SYSTEM -- TORQUE

SPECIFICATIONS -- TWIN TURBO .
2007 BMW 335i

12 31 ... REPLACING ALTERNATOR BELT PULLEY
 12 7 121
Illustrations show N42:
If fitted, remove cover cap from belt pulley.
Depending on alternator type, slacken screw with:
 Torx socket wrench

 Slacken multi-tooth socket wrench (special tool 12 7 122).
Grip freewheel with special tool 12 7 121.
Installation:

TWIN TURBO .
Remove alternator drive belt.
Release screw and if necessary remove freewheel.

2007 BMW 335i
Fig. 31: Identifying Special Tool (12 7 121) On Freewheel

12 31 009 CHECKING ALTERNATOR (BSD)
 Correct connections on charged battery

 Correct connections on alternator and starter motor
 Good ground connection between engine and body
 Tensioned ribbed V-belt
 Read out DME/DDE fault memory.
NOTE: The alternator with BSD interface can communicate with the engine control unit
(DME/DDE).
The alternator is not connected to the charge telltale light.
The alternator can identify various faults.
BSD alternator can be recognized by the plug connection on the alternator.
Connect diagnosis tester.
 Function selection
 Complete vehicle
 Drive
 Voltage and current regulation
 Voltage and current generation
 Alternator
 Follow instruction in diagnostic program
2007 BMW 335i
Oscillogram for a fault-free alternator:
Fig. 32: Identifying Oscillogram For Fault-Free Alternator Graph (1 Of 2)

Oscillogram for a faulty alternator:
One phase interrupted.
Repair/exchange alternator.
Fig. 33: Identifying Oscillogram For Fault-Free Alternator Graph (2 Of 2)

Interturn fault.
2007 BMW 335i
Fig. 34: Identifying Oscillogram For Fault-Free Alternator Graph - Interturn Fault
Open circuit in negative diode.
Fig. 35: Identifying Oscillogram For Fault-Free Alternator Graph - Open Circuit
Short circuit in positive diode.
2007 BMW 335i
Fig. 36: Identifying Oscillogram For Fault-Free Alternator Graph - Short Circuit
Open circuit in positive diode.
Fig. 37: Identifying Oscillogram For Fault-Free Alternator Graph - Open Circuit In Positive Diode
Open circuit in exciter diode.
2007 BMW 335i
Fig. 38: Identifying Oscillogram For Fault-Free Alternator Graph - Open Circuit In Exciter Diode
Assemble engine.
Check function of DME/DDE.
12 31 020 REMOVING AND INSTALLING OR REPLACING ALTERNATOR (N54)

 Disconnect battery negative lead and cover (See 61 20 900 DISCONNECTING AND CONNECTING
BATTERY NEGATIVE LEAD and/or 61 20 900 DISCONNECTING AND CONNECTING
BATTERY NEGATIVE LEAD )
 Remove charge-air duct
 Remove alternator drive belt
NOTE: In order to remove the alternator, it is necessary to remove the A/C compressor.
In so doing:
 Do not draw off A/C system refrigerant.

 Do not detach refrigerant lines from compressor.
 Do not remove compressor; instead, remove from bracket only and place to one side.
Remove compressor from bracket.
NOTE: For purposes of improved clarity, illustrations and description show

compressor removed.
Release bolts a few turns until bracket (1) is loose. Do not remove bracket (1).
2007 BMW 335i
Tightening torque 64 52 5AZ. See HEATING AND AIR CONDITIONING - TIGHTENING TORQUES -
COUPE or HEATING AND AIR CONDITIONING - TIGHTENING TORQUES - SEDAN .
Fig. 39: Locating Bracket Bolts

Remove protective cap and release nut underneath.

TWIN TURBO
Disconnect line (2).
Fig. 40: Locating Protective Cap

Unfasten screws.
Remove bracket (1) and alternator (2).

2007 BMW 335i

TWIN TURBO .
Fig. 41: Locating Bracket & Alternator

32 REGULATOR
12 32 501 REPLACING VOLTAGE REGULATOR

 Disconnect battery negative lead (See 61 20 900 DISCONNECTING AND CONNECTING
 Notes on removing and installing electronic control units (See 12 00 ... INSTRUCTIONS ON
COMPONENT TESTING and/or 12 00 ... INSTRUCTIONS FOR CONNECTING AND
DISCONNECTING TEST UNITS )
 Remove alternator
Bosch:
Release protective caps (1).

2007 BMW 335i
Fig. 42: Identifying Protective Caps

Bosch:
Release screw (1) and nuts (2), remove cover.
Fig. 43: Identifying Cover Screw & Nuts

Bosch:
Release screws and remove regulator switch (1) in direction of arrow.

2007 BMW 335i
Fig. 44: Removing Regulator Switch

Bosch:
Installation:
Clean contact surfaces and check pretension of contact spring, replace regulator switch if necessary.
Measurement A = min. 5 mm.
Check collector ring for wear and recondition if necessary.
Fig. 45: Identifying Collector Ring

Valeo:
Unscrew nut (1).
Slacken nut (2).

2007 BMW 335i
Release screws (3).
Release cover (4).
Fig. 46: Identifying Cover, Screws & Nut

Valeo:
Release screws.
Remove regulator switch (1) towards top.
Fig. 47: Identifying Regulator Switch

Valeo:
Installation:
Clean contact surfaces and check pretension of contact spring, replace regulator switch if necessary.
2007 BMW 335i
Measurement A = min. 5 mm.
Check collector ring for wear and recondition if necessary.
Fig. 48: Identifying Contact Spring Dimension

Installation:
Fit new regulator (1) with attached mounting sleeve (2) or locked carbon brush.
Pull off mounting sleeve (2) and replace with cover (3).
Fig. 49: Identifying Regulator, Mounting Sleeve & Cover

41 STARTER WITH MOUNTING

12 41 020 REMOVING AND INSTALLING/REPLACING STARTER (N52, N52K, N51, N53, N54)
IMPORTANT: Aluminum-magnesium materials.

2007 BMW 335i

corrosion.
damage) .

Unfasten nut.

TWIN TURBO .
Remove battery positive lead (2).
Fig. 50: Locating Battery Positive Lead

2007 BMW 335i
Release bolt (1).
Installation:

TWIN TURBO .
Release screws (2).
Installation:

TWIN TURBO .
Remove starter motor (3).
Fig. 51: Identifying Starter Motor

Installation:
Check starter pinion and ring gear for damage, replace starter motor if necessary.
12 41 041 REPLACING SOLENOID SWITCH
Turn off ignition.
Remove starter motor.
Release nut (1).

2007 BMW 335i
Remove cable lug (2).
Fig. 52: Identifying Cable Lug & Nut

CAUTION: Do not turn cable lug (2) while tightening down-risk of short circuit to
starter motor housing.
Tightening torque, 12 41 4AZ, see ENGINE ELECTRICAL SYSTEM --

TORQUE SPECIFICATIONS -- TWIN TURBO .
Release screws (1).
Fig. 53: Identifying Starter Motor Circuit Screws

Remove solenoid switch (1) and spring (2).
Unhook pin (3).
Installation:
2007 BMW 335i
Check pin (3) for wear and apply grease.
Fig. 54: Identifying Solenoid Switch, Spring & Unhook Pin

42 STARTER LEAD
12 42 500 REPLACING BATTERY POSITIVE LEAD (BETWEEN STARTER, ALTERNATOR AND
BATTERY POSITIVE TERMINAL)

Follow instructions for disconnecting and connecting battery (See 12 00 ... INSTRUCTIONS FOR
DISCONNECTING AND CONNECTING BATTERY and/or 12 00 ... INSTRUCTIONS FOR
DISCONNECTING AND CONNECTING BATTERY )
Remove protective cap (not shown).
Release screw, remove battery positive lead (1) from battery positive terminal.

TWIN TURBO .
2007 BMW 335i
Fig. 55: Locating Battery Positive Lead From Battery Positive Terminal
Remove protective cap and release nut underneath.

TWIN TURBO .
Disconnect battery positive lead (1) from alternator.
Fig. 56: Locating Battery Positive Lead From Alternator

Unfasten nut.

TWIN TURBO .
Disconnect battery positive lead (2) from starter motor.

2007 BMW 335i
Fig. 57: Locating Starter Motor Nut

Unclip battery positive lead (1) from holder (2) and remove.
Fig. 58: Identifying Battery Positive Lead & Holder

12 42 540 REPLACING SAFETY BATTERY TERMINAL (SBK)
CAUTION: Observe safety regulations.
Investigate cause of triggering of safety battery terminal. To do so, read

out fault memory of airbag control unit. Note fault messages stored in
memory. Rectify faults. Then clear fault memory.
Use of safety battery terminal:

2007 BMW 335i
 From model year 1998 in Series E38, E39, E46

 From 4/99 in E36/Z3
 in each of following new Series
The different models have different installation locations:
Battery in engine compartment
Safety battery terminal is replaced with cable up to battery positive support point.
Safety battery terminal is omitted as from 03/2002 from all E46 LHD models with 4-cylinder engines.
Battery in luggage compartment behind side trim panel
Remove side trim panel.
Follow instructions for disconnecting and connecting battery. (See 12 00 ... INSTRUCTIONS FOR
Disconnect and cover battery negative lead.
Fig. 59: Removing Side Trim Panel

Release front side trim panel partly and fold forward.

2007 BMW 335i
Fig. 60: Identifying Front Side Trim Panel Partly And Fold Forward
Battery in luggage compartment under floor trim panel
Fold back floor trim panel (1).
Lift cover (2) on battery negative lead.
Disconnect and cover battery negative lead (3).
Release nuts (4).
Remove battery cover.
Fig. 61: Identifying Back Floor Trim Panel Fold Position

Battery in luggage compartment under spare wheel

2007 BMW 335i
Remove spare wheel.
Release screws.
CAUTION: Do not kink air pipes.
Set air supply system (1) to one side.
Disconnect battery negative lead. (See 61 20 900 DISCONNECTING AND CONNECTING BATTERY
NEGATIVE LEAD and/or 61 20 900 DISCONNECTING AND CONNECTING BATTERY NEGATIVE
LEAD )
Fig. 62: Locating Spare Wheel Screws

Disconnect supply cable (1) for vehicle electrical system.
Installation:
Remove faulty fuses and carry out troubleshooting.

2007 BMW 335i
Fig. 63: Identifying Supply Cable

CAUTION: Pay attention to interface.
The repair cable is always a standard length.
The heavy-current connector of the repair cable has a larger diameter than
the battery positive lead.
In some Series (e.g. E46 touring), the heavy-current connector of the repair
cable can lead to installation problems.
This is the case when the interface is in the area of the close-fitting trim
panels.
Find matching interface (e.g. approx. 10 cm behind rear seat backrest in

E46 touring).
Lay repair cable parallel to battery positive lead.
Mark interface of battery positive lead at end of repair cable.

2007 BMW 335i
Fig. 64: Locating Battery Positive Lead Of Repair Cable

Release cable ties (1).
Fig. 65: Tying Cable

CAUTION: Do not use bolt cutters or similar tools to cut through the cable.
A cable end that has been squashed flat will no longer fit into the clamping
sleeve.
Saw through battery positive cable at marked point with an iron saw.
2007 BMW 335i
Fig. 66: Identifying Caution For Do Not Use Bolt Cutters

Strip insulation - length (A) - from cable end.
Distance (A) = 15 mm.
Fig. 67: Identifying Trip Insulation Length

Push heavy-current connector (1) over stripped cable end and screw into position.
2007 BMW 335i
Fig. 68: Identifying Heavy-Current Connector

Push shrink-fit hose (3) over repair cable.
Screw threaded sleeve (1) of repair cable (2) to heavy-current connector.
Fig. 69: Identifying Sleeve Of Repair Cable

Push shrink-fit hose (1) over connecting point and shrink on with a hot-air blower (2).
2007 BMW 335i
Fig. 70: Pushing Shrink-Fit Hose

NOTE: Heat up shrink-fit hose until it has settled completely around the connection
point.
Fig. 71: Locating Connection Point

When laying the repaired battery positive cable, observe the following:
 The shrink-fit hose must not be scuffed during any movement.

 The repair cable must not cause any disturbing noises during driving operation.
NOTE: Offsetting cutting line by approx. 10 cm produces excess length of battery

positive lead (1).
Lay battery positive lead (1) without kinks or abrasions. (Shown on E46
touring.)
2007 BMW 335i
Fig. 72: Locating Battery Positive Lead

51 ENGINE WIRING LOOM

12 51 001 REPLACING WIRING HARNESS SECTION FOR ENGINE (N54)
protection). (See 61 35 ... NOTES ON ESD PROTECTION (ELECTRO STATIC
DISCHARGE) and 61 35 ... NOTES ON ESD PROTECTION (ELECTRO STATIC
DISCHARGE) )

 Remove charge air duct
Remove cover (3).

2007 BMW 335i

Release grommet (2) from electronics box.
Installation:
Make sure grommet (2) is correctly seated in housing (watertightness).
Raise control unit (3) slightly.
Fig. 74: Identifying Control Unit Grommet

Unlock plugs (1) using slide in direction of arrow and disconnect.

2007 BMW 335i
Fig. 75: Removing Plugs

Short plug:
Unlock slide (2) in bore holes (1) and pull out of housing.
Unlock tab (3), pull contact carrier (4) in direction of arrow out of housing.
Fig. 76: Pulling Out Of Housing

Long plug:
Press locking tab (1) in direction of arrow and pull contact carrier (2) out of housing.
Unlock and disconnect all plug connections of engine wiring harness section in electronics box.
2007 BMW 335i
Fig. 77: Pressing Locking Tab

WORK STEP TABLE

Work step Note:
Unlock plug connections on control sensors and -
disconnect
Unlock plug on heating tube and disconnect -
Unlock plug on alternator and disconnect -
Unlock plug connection on knock sensors and -
disconnect
Unlock plug on crankshaft sensor and disconnect -
Unlock plug on starter motor and disconnect -
Unlock plug on high-pressure pump and disconnect -
Unlock plug on low-pressure sensor and disconnect -
Unlock plug on A/C compressor and disconnect -
Remove rear underbody protection -
Unlock plug connections on monitor sensors and -
disconnect
Unlock plug on oil condition sensor and disconnect -
12 51 100 REPLACING WIRING HARNESS SECTION FOR IGNITION COIL (N54)
IMPORTANT: Aluminum-magnesium materials.

corrosion.
2007 BMW 335i
Aluminum screws/bolts must be replaced each time they are released.
damage) .
DISCHARGE) )

 Remove acoustic cover (See 11 00 REMOVING AND INSTALLING/REPLACING ACOUSTIC
COVER (N52) )
 Remove intake duct (See 13 REMOVING INTAKE DUCT (N52/N52K/N51/N53) )
Remove cover (3).

2007 BMW 335i
Unlock control unit (2) and raise approx. 5 cm.
Fig. 79: Identifying Control Unit

Fig. 80: Pressing Locking Tab (1 Of 2)

Press locking tabs (1) in direction of arrow and pull contact carrier (2) out of housing.
2007 BMW 335i
Fig. 81: Pressing Locking Tab (2 Of 2)

Fig. 82: Pulling Contact Carrier Out Of Housing

Release screws and remove cable duct (1).
Installation:

TWIN TURBO .
2007 BMW 335i
Fig. 83: Identifying Cable Duct

WORK STEP TABLE

Work step Note:
Disconnect positive lead at jump-start connection -
point
Unlock plug connections on ignition coils and -
disconnect
Unlock plug on injectors and disconnect -
Release ground connections -
Unlock plug on pressure transducers and disconnect -
Unlock plug on both solenoid valves and disconnect -
Unlock plug on inlet and exhaust camshaft sensors -
and disconnect
Unlock plug for high-pressure sensor and disconnect -
Unlock plug on oil pressure switch and disconnect -
Unlock plug on coolant temperature sensor and -
disconnect
Remove front underbody protection (See 51 47 490 -
REMOVING AND INSTALLING/REPLACING
FRONT ASSEMBLY UNDERSIDE
PROTECTION and/or 51 47 490 REMOVING
AND INSTALLING/REPLACING FRONT
ASSEMBLY UNDERSIDE PROTECTION )
Unlock plug on electric coolant pump and -
disconnect
Unlock plug on coolant thermostat and disconnect -
Release ground connection on engine next to coolant Tightening torque 12 52 3AZ. Replace screw. See
pump ENGINE ELECTRICAL SYSTEM -
TIGHTENING TORQUES - COUPE .
2007 BMW 335i
61 OIL PRESSURE-OIL TEMPERATURE

12 61 280 REMOVING AND INSTALLING/REPLACING OIL PRESSURE SENSOR (N52, N52K, N51,
N54, N53)

 N52, N52K, N51, N53 only:
 Remove ignition coil cover
 N54 only:
 Remove intake filter housing
Only perform this task on an engine that has cooled down.
Installation location:
Oil filter housing, front left.
Engine oil may emerge when oil pressure sensor is replaced; have a cleaning cloth ready.
Release oil pressure sensor (2).

TWIN TURBO .
Installation:
Check engine oil level, top up engine oil if necessary.

2007 BMW 335i
Fig. 84: Identifying Oil Pressure Sensor & Plug

12 61 285 REPLACING ENGINE OIL LEVEL SENSOR (N52, N52K, N51, N46, N54, N53)
DISCHARGE) )

 E60/E63/E64/E83/E85/E86/E70 only: Remove reinforcement plate (See 12 61 285 REPLACING
ENGINE OIL LEVEL SENSOR (N52, N52K, N51, N46, N54, N53) and/or 12 61 285 REPLACING
ENGINE OIL LEVEL SENSOR (N52, N52K, N51, N46, N54, N53) )
 E81/E87/E90/E91/E92/E93 only: Remove underbody protection (See 51 47 490 REMOVING AND
INSTALLING/REPLACING FRONT ASSEMBLY UNDERSIDE PROTECTION )
 Drain off engine oil (See 00 00 610 ENGINE OIL SERVICE (N52K) and/or 00 00 610 ENGINE OIL
SERVICE INCL. SUPPLEMENTARY SERVICE (N52) )
Unscrew nuts.

TWIN TURBO .
Remove oil level sensor (2).
Installation:
Clean sealing face on oil sump.

2007 BMW 335i
Replace seal on oil level sensor.
An excessively low torque value will result in oil leaks.
An excessively high torque value will result in damage to the oil level sensor.
Top up engine oil.
Fig. 85: Locating Oil Level Sensor Nut

90 CONTROL UNIT BOX

12 90 ... REMOVING AND INSTALLING/REPLACING ELECTRONICS BOX
DISCHARGE) )
NOTE: Follow instructions for removing and installing electronic control units (See 12
00 ... INSTRUCTIONS FOR REMOVING AND INSTALLING ELECTRONIC
CONTROL UNITS and/or 12 00 ... INSTRUCTIONS FOR REMOVING AND
INSTALLING ELECTRONIC CONTROL UNITS )
 Read fault memory.

 Disconnect negative battery cable (See 61 20 900 DISCONNECTING AND CONNECTING
 Remove both windscreen wiper arms (See 61 61 100 REMOVING AND INSTALLING/REPLACING
BOTH WINDSCREEN WIPER ARMS and/or 61 61 100 REMOVING AND
2007 BMW 335i
INSTALLING/REPLACING BOTH WINDSCREEN WIPER ARMS )

COVER and/or 51 13 116 REMOVING AND INSTALLING COWL PANEL COVER )
 Remove tension strut on spring strut dome on right (See 51 71 371 REMOVING AND
INSTALLING/REPLACING TENSION STRUT ON LEFT OR RIGHT SPRING STRUT DOME
and/or 51 71 371 REMOVING AND INSTALLING/REPLACING TENSION STRUT ON LEFT
OR RIGHT SPRING STRUT DOME )
Release screws (1).
Slacken nut (2).
Lift out right end panel (3).
Installation:
Ensure gasket (4) is correctly seated.
Fig. 86: Lifting Out Right End Panel

Remove cover (3).

2007 BMW 335i

Lift out plug connection (2), fuse carrier (3) and wiring harness grommet (4) from electronics box (1).
Installation:
Make sure wiring harness grommets (4) are correctly seated in electronics box (1).
Fig. 88: Identifying Wiring Harness Grommets

Unlock DME control unit at holders (1) and raise slightly.
Pull tab (3) in direction of arrow out of housing and disconnect plug connections (2) on DME control unit.
2007 BMW 335i
Fig. 89: Pulling Tab Disconnecting Plug Connections On DME Control Unit
If necessary, press locking tabs (1) in direction of arrow and pull contact carrier (2) out of housing.

If necessary, press locking tab (1) in direction of arrow and pull contact carrier (2) out of housing.
2007 BMW 335i
Fig. 91: Pressing Locking Tab

Unlock control unit carrier (2) at holder (1) and remove.
Remove DME control unit (3).
Fig. 92: Removing DME Control Unit

Unlock control unit carrier (2) at holder (1) and remove.
Fig. 93: Identifying Control Unit Carrier & Holder

Remove control unit carrier (1) from electronics box.

2007 BMW 335i
Fig. 94: Identifying Control Unit Carrier From Electronics Box

Release screws (1).
Replacement:
Modify water drain valve (2) and bump stop (3).
Fig. 95: Identifying Water Drain Valve & Bump Stop

Installation:
Make sure gasket (1) is correctly seated on electronics box.

2007 BMW 335i
Fig. 96: Identifying Electronics Box Gasket

12 90 ... REMOVING AND INSTALLING/REPLACING ELECTRONICS BOX
DISCHARGE) )
NOTE: Follow instructions for removing and installing electronic control units (See 12
00 ... INSTRUCTIONS FOR REMOVING AND INSTALLING ELECTRONIC
CONTROL UNITS and/or 12 00 ... INSTRUCTIONS FOR REMOVING AND
INSTALLING ELECTRONIC CONTROL UNITS )
 Read fault memory.

 Disconnect negative battery cable (See 61 20 900 DISCONNECTING AND CONNECTING
 Remove both windscreen wiper arms (See 61 61 100 REMOVING AND INSTALLING/REPLACING
BOTH WINDSCREEN WIPER ARMS and/or 61 61 100 REMOVING AND
INSTALLING/REPLACING BOTH WINDSCREEN WIPER ARMS )
COVER and/or 51 13 116 REMOVING AND INSTALLING COWL PANEL COVER )
 Remove tension strut on spring strut dome on right (See 51 71 371 REMOVING AND
INSTALLING/REPLACING TENSION STRUT ON LEFT OR RIGHT SPRING STRUT DOME
and/or 51 71 371 REMOVING AND INSTALLING/REPLACING TENSION STRUT ON LEFT
OR RIGHT SPRING STRUT DOME )
2007 BMW 335i
Release screws (1).
Slacken nut (2).
Lift out right end panel (3).
Installation:
Ensure gasket (4) is correctly seated.
Fig. 97: Lifting Out Right End Panel

Remove cover (3).

2007 BMW 335i
Unlock plug connection (2) in direction of arrow and disconnect.
Pull wiring harness grommet (5) out of electronics box and remove wiring harness (4).
Pull wiring harness grommet (3) out of electronics box and remove wiring harness with control unit carrier (6).
Installation:
Make sure wiring harness grommets (3, 5) are correctly seated in electronics box.
Fig. 99: Identifying Wiring Harness Grommets

If necessary, press locking tabs (1) in direction of arrow and pull contact carrier (2) out of housing.

If necessary, press locking tab (1) in direction of arrow and pull contact carrier (2) out of housing.
2007 BMW 335i

Release screws (1).
Replacement:
Modify water drain valve (2) and bump stop (3).
Fig. 102: Identifying Water Drain Valve & Bump Stop

Installation:
Make sure gasket (1) is correctly seated on electronics box.

2007 BMW 335i
Fig. 103: Identifying Electronics Box Gasket

2007 BMW 335i
ENGINE Exhaust System - Repair
ENGINE
Exhaust System - Repair
EXHAUST SYSTEM, COMPLETE

18 00 020 REMOVING AND INSTALLING COMPLETE EXHAUST SYSTEM (N54)
 31 2 220

These tasks should only be carried out on an exhaust system that has
cooled down.
IMPORTANT: Removal of the exhaust system must be carried out with the assistance of a
second person.
E91, E92, E93 only:
 Remove tension strut on rear axle.
Support exhaust system with jack and special tool 31 2 220 and secure against falling out.
Fig. 1: Supporting Exhaust System With Jack And Special Tool 31 2 220
2007 BMW 335i
Unscrew nuts.
Installation:
Replace seal.
Fig. 2: Locating Self-Locking Nuts

Release bolt and remove bracket (1).

2007 BMW 335i
Fig. 3: Locating Bolt And Bracket

Release bolts along line and remove reinforcement plate (1).
Fig. 4: Identifying Bolts And Reinforcement Plate

Unscrew nuts.

2007 BMW 335i
Fig. 5: Identifying Nuts And Holder

Pull off hose.
Release screws (1).
Unscrew nuts (2).
Lower and remove exhaust system with assistance of a second person.

2007 BMW 335i
Fig. 6: Identifying Hose, Screws And Nuts

Installation:
Check exhaust system for leaks.
MUFFLERS, PETROL
18 12 045 REMOVING AND INSTALLING/REPLACING CENTER SILENCER (N54)
 00 2 210
WARNING: Risk of burning!

This repair work may only be carried out on an exhaust system which has
cooled down.
 Remove EXHAUST SYSTEM
NOTE: Interfaces for the center silencer (3) are marked with a notch in the pipe.
Fig. 7: Identifying Exhaust Pipe With Catalytic Converter

Disconnect and deburr exhaust pipes in the marked areas using commercially available workshop materials and
2007 BMW 335i
Fig. 8: Disconnecting Exhaust Pipes In Marked Areas Using Commercially Available Workshop
Materials And Special Tools 00 2 210
Installation note:
Connect and align the center silencer with both exhaust pipes using clamps.
Align and tighten clamps.
Fig. 9: Aligning Centre Silencer With Both Exhaust Pipes Using Clamps
2007 BMW 335i
Installation note:
Connect and align center silencer with both rear silencers using clamps.
Align and tighten clamps.
Fig. 10: Aligning Centre Silencer With Both Rear Silencers Using Clamps
NOTE: Check exhaust system for leaks.
18 12 030 REMOVING AND INSTALLING/REPLACING REAR MUFFLER (N54)
 00 2 210
 31 2 220

Only perform these tasks after exhaust system has cooled down.
NOTE: Illustrations show and descriptions refer to the left rear muffler.
The procedure is identical for the right filter side.
Support rear muffler with special tool 31 2 220.

2007 BMW 335i
Fig. 11: Supporting Rear Muffler With Special Tool 31 2 220

NOTE: Cutting lines for rear muffler (4) are designated by a notch in the pipe.

Cut exhaust pipes with special tool 00 2 210 at marked points and deburr.
2007 BMW 335i
Fig. 13: Cutting Exhaust Pipes With Special Tool 00 2 210 At Marked Points And Deburr
Unfasten nut.
Fig. 14: Locating Nut

Pull off hose.
Release screw (1).

2007 BMW 335i
Lower rear muffler (2) and remove.
Fig. 15: Identifying Screw And Rear Muffler

Installation:
Connect rear muffler to center muffler and right rear muffler by means of clamping sleeves.
Align rear muffler to rear apron.
Align clamp and tighten down.

2007 BMW 335i
Fig. 16: Aligning Rear Muffler To Rear Apron

EXHAUST CATALYTIC CONVERTER

18 32 050 REMOVING AND INSTALLING/REPLACE CATALYTIC CONVERTER FOR
CYLINDERS 1-3 (N54, N54T)
 18 0 110

cooled down.
 Remove underbody protection.

 Remove EXHAUST SYSTEM.
 Remove cable clip on side of transmission for control sensor/monitoring sensor.
 All-wheel drive vehicles only:
Remove right bearing support.
NOTE: The oxygen sensors are in danger of being damaged when the exhaust
manifolds are removed and installed.
Remove monitoring sensor from cylinders 1 to 3. See 11 78 545 REMOVING AND

INSTALLING/REPLACING BOTH LAMBDA OXYGEN MONITOR SENSORS (N54) .
Remove control sensor, cylinders 1 to 3. See 11 78 513 REMOVING AND INSTALLING/REPLACING

BOTH LAMBDA OXYGEN CONTROL SENSORS (N54) .
Unscrew nuts.

2007 BMW 335i
Fig. 17: Locating Nuts

Release screws.
Remove holder (1).
Fig. 18: Identifying Screws And Holder

Unfasten clamp. In so doing, secure catalytic converter (1) against falling out.
Feed out catalytic converter (1) towards bottom and remove.

2007 BMW 335i
Installation note:
Clean sealing surface. Replace seal and clamp.
Fig. 19: Identifying Catalytic Converter

Installation note:
Secure installation position of catalytic converter with special tool 18 0 110 .

2007 BMW 335i
18 32 060 REMOVING AND INSTALLING/REPLACE CATALYTIC CONVERTER FOR

CYLINDERS 4-6 (N54, N54T)
 18 0 110

cooled down.
 Remove the CATALYTIC CYLINDER 1-3.
NOTE: The oxygen sensors are in danger of being damaged when the exhaust
manifolds are removed and installed.
Remove monitoring sensor from cylinders 4 to 6. See 11 78 545 REMOVING AND

INSTALLING/REPLACING BOTH LAMBDA OXYGEN MONITOR SENSORS (N54) .
Remove control sensor, cylinders 4 to 6. See 11 78 513 REMOVING AND INSTALLING/REPLACING

BOTH LAMBDA OXYGEN CONTROL SENSORS (N54) .
Unfasten clamp. In so doing, secure catalytic converter (1) against falling out.
Feed out catalytic converter (1) towards bottom and remove.
Installation note:
Clean sealing surface. Replace seal and clamp.

2007 BMW 335i
Fig. 21: Identifying Clamp Bolt And Catalytic Converter

Installation note:
Secure installation position of catalytic converter with special tool 18 0 110 .

18 32 081 REMOVING AND INSTALLING/REPLACE EXHAUST PIPE WITH CATALYTIC

2007 BMW 335i
CONVERTER FOR CYLINDERS 1-3 (N54)
 00 2 210

cooled down.
 E91, E92, E93 only:
Remove trailing link.
NOTE: Interface for exhaust pipe (1) is designated by a notch in the pipe.

Cut exhaust pipe with special tool 00 2 210 at marked point and deburr.
2007 BMW 335i
Fig. 24: Cutting Exhaust Pipe With Special Tool 00 2 210 At Marked Point And Deburr
Release nuts for left exhaust pipe.
Installation note:
 Replace self-locking nuts.

 Replace gasket.
 Tightening torque 18 00 1AZ .
Fig. 25: Locating Self-Locking Nuts

2007 BMW 335i
Release screw.
Take off holder (1) and remove exhaust pipe.
Fig. 26: Identifying Holder And Exhaust Pipe

Installation note:
Connect exhaust pipe to center silencer by means of clamp and align.

2007 BMW 335i
Fig. 27: Aligning Exhaust Pipe Clamps

18 32 082 REMOVING AND INSTALLING/REPLACE EXHAUST PIPE WITH CATALYTIC

CONVERTER FOR CYLINDERS 4-6 (N54)

cooled down.
 Remove EXHAUST SYSTEM.
NOTE: Interface for exhaust pipe (2) is designated by a notch in the pipe.
Disconnect and deburr exhaust pipe (2) at marked position.

2007 BMW 335i

Installation note:
Connect exhaust pipe to center silencer by means of clamp and align.
Fig. 29: Aligning Exhaust Pipe Clamps

2007 BMW 335i

2007 BMW 335i
SUSPENSION Front Axle - Repair Instructions - 3-Series
SUSPENSION
Front Axle - Repair Instructions - 3-Series
GENERAL
STOP FUNCTION (MSA)

 Headaches
 Dizziness
 Stomach aches
 Vomiting
 Diarrhoea
 Cramps/fits
 Unconsciousness

First aid measures:
2007 BMW 335i
Danger of injury!
 Impaired sight

First aid measures:

Recycling:
Measures if oil is unintentionally released:
2007 BMW 335i
00...... RAISING VEHICLE WITH TROLLEY JACK
IMPORTANT: Observe the following trolley-jack-related instructions:
1. Use only BMW-distributed/approved trolley jacks which have rubber plate

contact points.
2. Trolley jacks must be regularly serviced and always checked for
functional reliability before they are used!
3. Check the rubber plate on the trolley jack prior to each use, replacing if
necessary.
Fig. 1: Identifying Trolley-Jack

WARNING: The vehicle may be raised with a trolley jack only at the following jacking
points!
1. Car jacking point on reinforcement strut (rear-wheel drive)

2. Side car jacking points
3. Rear differential
Risk of damage: It is not permitted to raise the vehicle at the rear differential cover!
2007 BMW 335i
Fig. 2: Identifying Jacking Point

1. Car jacking point on front axle carrier (all-wheel drive)
Fig. 3: Identifying Car Jacking Point On Front Axle Carrier

31... FRONT AXLE OVERVIEW

2007 BMW 335i
Fig. 4: Identifying Front Axle Components

31.... LAYOUT OF SPRING STRUT SHOCK ABSORBER

2007 BMW 335i
Fig. 5: Layout Diagram Of Spring Strut Shock Absorber

31 00... FRONT AXLE + STEERING: WHEEL/CHASSIS ALIGNMENT CHECK MUST BE

CARRIED OUT AFTER THE FOLLOWING WORK
2007 BMW 335i
Fig. 6: Identifying Front Axle And Steering Wheel/Chassis Components

 Release of following screw/bolt connections:

 Steering gear to front axle carrier
 Control arm to front axle carrier
 Support bearing to body (if centering pin is missing)
 Tie rod end to tie rod
 Replacement of following parts:

1. Front axle carrier
2. Steering gear
3. Gaiter (if the tie rod end has to be screwed off)
4. Control arm
5. Support bearing (if centering pin is missing)
6. Swivel bearing
7. Tie rod end
8. Tie rod
31 00... INFORMATION ON REPLACING SHOCK ABSORBERS

2007 BMW 335i
Facts:
When a shock absorber is faulty on one side (leaking, noises, limit values exceeded on the shock tester), often
both shock absorbers on the axle in question are replaced.
Consequence:
This is not necessary for technical reasons and causes the manufacturer not to recognize the unnecessarily
removed shock absorbers as damaged parts. Unnecessarily high costs for the customer can be avoided by
replacing the shock absorber on one side only.
Procedure:
Shock absorbers may be replaced on one side only until they have completed 50 000 km service.
Exception: On all M-GmbH models, when a limit value is exceeded on one side, it is still necessary always to
replace both shock absorbers on the relevant axle.
31 00... INSTRUCTIONS (CHASSIS COMPONENTS MADE OF ALUMINUM)
Due to the chemical and corrosion characteristics of aluminum, always comply with the following points when
handling aluminum components:
 Do not bring into contact with battery acid!

 Do not clean with wire brushes made of brass or iron! Always use wire brushes with stainless steel
bristles!
 Do not expose to flying sparks when grinding/separating! Cover components!
 Do not strike with steel welding splashes! Cover components!
 Do not expose to temperatures > 80°C, even for brief periods! Temperatures in paint facilities do not have
the same impact
NOTE: Damaged threads in engine carrier may be repaired with Helicoil thread inserts.
Comply with the procedure described in the example.
2007 BMW 335i
Fig. 7: Identifying Helicoil Damaged Thread

Procedure:
1. Create a clean core hole; if necessary, drill out screw remnants
Fig. 8: Drilling Out Screw Remnants

2. Create locating thread for Helicoil thread insert

2007 BMW 335i
Fig. 9: Making Thread For Helicoil Thread

3. Pick out Helicoil thread insert in accordance with the table and screw into the locating thread until flush
with the original thread
Fig. 10: Removing Helicoil Thread

4. Break drive pin and remove

2007 BMW 335i
Fig. 11: Identifying Drive Pin

FRONT AXLE SUSPENSION

31 10 000 REMOVING AND INSTALLING COMPLETE FRONT AXLE (WITH SPRING STRUTS)
IMPORTANT: Before removing front axle carrier:
In order to avoid damage to lifting platform, perform weight compensation on

vehicle.
Load spring strut domes with sand bags.
WARNING: Danger to life!

Secure engine in installation position to prevent it from falling down. See
11 00 670 SECURING ENGINE IN INSTALLATION POSITION (N51) or 11 00
670 SECURING ENGINE IN INSTALLATION POSITION (N52K, N53) .
Danger of poisoning if oil is ingested/absorbed through the skin! Risk of
injury if oil comes into contact with eyes and skin!
IMPORTANT: Adhere to the utmost cleanliness. Do not allow any dirt to enter the hydraulic
system.
Close off pipe connections with plugs.
 Secure engine in installation position. See 11 00 670 SECURING ENGINE IN INSTALLATION

POSITION (N51) or 11 00 670 SECURING ENGINE IN INSTALLATION POSITION (N52K,
N53) .
 Disconnect battery negative lead. See 61 20 900 DISCONNECTING AND CONNECTING
BATTERY NEGATIVE LEAD .
2007 BMW 335i
 Remove brake caliper on both sides from swivel bearing and tie back. See 34 11 020 REMOVING AND
INSTALLING OR REPLACING FRONT LEFT OR RIGHT BRAKE CALLIPER (TRW) or 34 11
020 REMOVING AND INSTALLING OR REPLACING FRONT LEFT OR RIGHT BRAKE
CALLIPER (TEVES) .
 Detach plug connection for pulse generator on both sides and expose line up to holder on spring strut
 Remove front assembly underside protection. See 51 47 490 REMOVING AND INSTALLING /
REPLACING FRONT ASSEMBLY UNDERSIDE PROTECTION .
 If necessary, remove radiator seal
 If necessary, remove steering gear cover on left and right
 Remove reinforcement strut / V-strut
 E93: Remove diagonal struts from mounting fixture
 Remove lower section of steering spindle from steering gear 32 31 070 REMOVING AND
INSTALLING / REPLACING LOWER SECTION OF STEERING SPINDLE
 If necessary, disconnect plug connection from ride-height sensor
 If necessary, disconnect vacuum line from electrically operated valve to engine mounts at T-piece
Version with power steering:
 Draw off and dispose of hydraulic fluid from fluid reservoir.

 Disconnect pressure line from vane pump.32 41 060 REMOVING AND INSTALLING OR
REPLACING POWER STEERING VANE PUMP (N51, N52, N53)
 335 d: Disconnect cooler return line from power steering loop.
 Detach return line from power steering cooler and expose line up to connection on power steering gear.32
41... NOTES ON HYDRAULIC LINE WITH QUICK-CONNECT COUPLING
Version with active steering:
Disconnect plug connections (1) and unclip connecting line (2) from front axle carrier.
Fig. 12: Disconnect Plug Connections (1) And Unclip Connecting Line (2) From Front Axle Carrier
2007 BMW 335i
Version with Electric Power Steering (EPS):
Disconnect plug connections (1) and expose wiring harness up to engine carrier.
Installation: Plug connections must audibly snap into place. Make sure wiring harness is correctly laid.
Fig. 13: Disconnect Plug Connections (1) And Expose Wiring Harness Up To Engine Carrier
IMPORTANT: Guide spring struts with your hand when lowering and raising in order to avoid
damaging the wheel arches. After lowering, the spring struts must be aligned
to the front axle carrier and secured in such a way that the ball joints of the
control arms, tension struts and tie rod ends are not damaged.
Remove both spring struts from spring strut dome. Lower front axle carrier.
After installation:
 Fill and bleed hydraulic system. See 32 13 006 BLEEDING POWER STEERING UNIT .
 Check pipe connections for leaks
 Carry out wheel alignment check if a spring strut with support bearing was or has been installed without
centering pin. See 32 00 150 KDS CHASSIS/WHEEL ALIGNMENT CHECK WITH LOAD UP TO
DESIGN POSITION or 32 00 155 KDS CHASSIS/WHEEL ALIGNMENT CHECK WITH RIDE-
HEIGHT MEASUREMENT WITHOUT LOAD .
 Carry out steering angle sensor adjustment/adjustment for active front steering. See 61 31 996 CARRY
OUT STEERING ANGLE SENSOR ADJUSTMENT or 32 10 005 ADJUSTMENT FOR ACTIVE
FRONT STEERING .
51 47 490 REMOVING AND INSTALLING / REPLACING FRONT UNDERBODY PROTECTION
NOTE: Illustration created using E87 120i as an example. There may be differences in
detail in the case of other models.
2007 BMW 335i
Release screws (1).
Installation:
Fig. 14: Identifying Screws, Underbody Protection And Under Bumper Trim
51 47 491 REMOVING AND INSTALLING/REPLACING REAR UNDERBODY PROTECTION
Single-part underbody protection (without E90/E91/E92 AWD):
Release screws (1).
Pull underbody protection (2) in direction of arrow out of bracket (3).
Installation:

2007 BMW 335i
Fig. 15: Pulling Underbody Protection Out Of Bracket

Two-part underbody protection
Release screws (1).
Detach underbody protection (2) from bracket (3) and remove.
Installation:
Fig. 16: Identifying Screws, Underbody Protection And Bracket

Single-part underbody protection (E90/E91/E92 AWD):

2007 BMW 335i
Release screws (1).
Remove underbody protection (2) downwards.
Installation:
Fig. 17: Identifying Centre Underbody Protection And Screws

FRONT SUB-FRAME
31 11 001 REPLACING FRONT AXLE CARRIER
IMPORTANT: Before removing front axle carrier: In order to avoid damage to lifting platform,
perform weight compensation on vehicle. Load spring strut domes with sand
bags.


N53) .
 Disconnect battery negative lead. See 61 20 900 DISCONNECTING AND CONNECTING
BATTERY NEGATIVE LEAD .
2007 BMW 335i
 Remove front wheels. See 10 WHEELS .

 Remove front stabilizer bar.
 E90, E91, E92: Remove stiffening strut
 E93: Remove V-strut
 E93: Remove mounting fixture
 Remove lower section of steering spindle from steering gear. See 32 31 070 REMOVING AND
INSTALLING / REPLACING LOWER SECTION OF STEERING SPINDLE .
 If necessary, disconnect plug connection from ride-height sensor
 If necessary, disconnect vacuum line from electrically operated valve to engine mounts at T-piece
 Remove tension strut on both sides from front axle carrier.
 Remove both control arms from front axle carrier.
 Remove both tie rods on steering gear. See 32 21 231 REPLACING LEFT OR RIGHT TIE ROD .
NOTE: Front axle carrier is lowered without power steering gear.
Disconnect plug connections (1) and unclip connecting line (2) from front axle carrier.
Fig. 18: Disconnect Plug Connections And Unclip Connecting Line From Front Axle Carrier
Disconnect plug connection (1) from power steering pump and expose connecting cable up to front axle carrier.
Disconnect plug connections (2) on power steering gear

2007 BMW 335i
Build date up to 03/2007: Disconnect plug connection on cumulative steering angle sensor.
Fig. 19: Disconnect Plug Connections On Power Steering Gear

Lower front axle carrier a little. See 31 11 506 Lowering/raising front axle carrier (SWZ00-2040).
If necessary, remove heat shield above right tie rod gaiter. Remove steering gear from front axle carrier and tie
up. Lower front axle carrier.
Remove heat shield(s) from front axle carrier. If necessary, remove wiring harness (1) for active front steering
from front axle carrier. Remove both engine mounts (2). See 11 ENGINE SUSPENSION . On M57T2:
Release bolts and remove both support angles (3). Tightening torque, see 31 10 4AZ in 31 10 FRONT AXLE
SUSPENSION .
Fig. 20: Identifying Wiring Harness, Engine Mounts And Support Angles
If necessary, disconnect vacuum line (1). If necessary, release bolts and remove reinforcement plates (2).
2007 BMW 335i
Installation: Use previous front axle carrier as a template for modifying or replacing small parts. Tightening
torque, see 31 10 5AZ in 31 10 FRONT AXLE SUSPENSION .
Fig. 21: Identifying Vacuum Line And Reinforcement Plates

After installation:
 Perform chassis alignment check. See 32 00 150 KDS CHASSIS/WHEEL ALIGNMENT CHECK
WITH LOAD UP TO DESIGN POSITION or 32 00 155 KDS CHASSIS/WHEEL ALIGNMENT
CHECK WITH RIDE-HEIGHT MEASUREMENT WITHOUT LOAD .
FRONT STEERING .
31 11 004 REMOVING AND INSTALLING/REPLACING REINFORCEMENT BRACE
IMPORTANT: Observe safety instructions for raising the vehicle

Driving without the reinforcement brace is not permitted!
 Remove reinforcement cover on both sides. See 51 71... REMOVING AND
INSTALLING/REPLACING LEFT/RIGHT REINFORCEMENT COVER .
Partly detach underbody panelling on both sides in area of reinforcement brace. See 51 47... REMOVING
AND INSTALLING/REPLACING LEFT OR RIGHT UNDERBODY PANELLING .
Release screws (1).
Remove reinforcement brace (2).

2007 BMW 335i
Installation:
Replace screws and insertion nuts.
Tightening torque, see 31 10 2AZ in 31 10 FRONT AXLE SUSPENSION .
Fig. 22: Identifying Screws And Reinforcement Brace

31 11 506 LOWERING/RAISING FRONT AXLE CARRIER (SWZ00-2040)
IMPORTANT: Before lowering front axle support: In order to avoid damage to lifting platform,
bags.

IMPORTANT: N47, N57: Danger of short-circuiting at starter!

N53) .
 Remove reinforcement brace/V-strut on left and right.
2007 BMW 335i
 E93: Remove diagonal struts from mounting fixture

 If necessary, disconnect plug connection from ride-height sensor.
 If necessary, disconnect vacuum line from electrically operated valve to engine mounts at T-piece.
Cut open cable tie (1) for connecting line on front axle carrier.
Fig. 23: Cut Open Cable Tie (1) For Connecting Line On Front Axle Carrier

Failure to comply with the following instructions may result in the vehicle
slipping off the lifting platform and critically injuring other persons.
When supporting components, make sure that
 the vehicle can no longer be raised or lowered

 the vehicle does not lift off the locating plates on the lifting platform
If necessary, position special tool 00 2 040 with a 2nd person helping on workshop jack.
Insert special tools 31 4 051 and 31 4 060 into corresponding mountings of special tool 00 2 040.
Align special tool 00 2 040 to front axle carrier.
NOTE: Make sure when raising that special tools 31 4 060 are correctly inserted in the
rear recesses on the front axle carrier.
If necessary, lower special tool 33 3 274. Support front axle carrier by raising special tool 00 2 040.
2007 BMW 335i
Fig. 24: Identifying Special Tools On Workshop Jack

IMPORTANT: Pay attention to power steering hoses and lines when lowering and raising.
Hoses/lines must not be kinked/tensioned/bent!
Release bolts (1-3).
Lower front axle carrier max. 10 cm; if necessary, disconnect cooler return line/coolant pipe from front axle
carrier.
Installation:
Check threads for damage; if necessary, repair with Helicoil thread inserts.
 Bolt (1) M12x90

 Bolt (2) M12x145
 Bolt (3) M12x53
Tighten down first screws (1) and then screws (2, 3). Tightening torque, see 31 10 1AZ in 31 10 FRONT
AXLE SUSPENSION .
2007 BMW 335i

After installation:
FRONT STEERING .
31 11 506 LOWERING/RAISING FRONT AXLE SUPPORT (UNIVERSAL LIFTER)
IMPORTANT: Before lowering front axle support: In order to avoid damage to lifting platform,
bags.

IMPORTANT: N47, N57: Danger of short-circuiting at starter!

N53) .
 E90, E91, E92: Remove stiffening strut
2007 BMW 335i
 E88, E93: Remove V-strut on left and right

 If necessary, disconnect plug connection from ride-height sensor.
 If necessary, disconnect vacuum line from electrically operated valve to engine mounts at T-piece.
Cut open cable tie (1) for connecting line on front axle carrier.
Fig. 26: Cut Open Cable Tie (1) For Connecting Line On Front Axle Carrier

When supporting components, make sure that:

Engage 31 5 251 with a 2nd person helping completely on workshop jack 00 2 030.
Insert special tools 31 5 253 in telescopic supports of a profile rail pair.

2007 BMW 335i
Fig. 27: Identifying Universal Lifter

NOTE: In a profile rail pair two profile rails are connected to each by toothing.
Insert special tools 31 5 256 in telescopic supports of other profile rail pair.
NOTE: The jacking points on the left side are shown.
Align special tools 31 5 253 and 31 5 256 to front axle support. Support front axle support by operating
workshop jack 00 2 030.
Fig. 28: Aligning Special Tools 31 5 253 And 31 5 256 To Front Axle Support
IMPORTANT: Pay attention to power steering hoses and lines when lowering and raising.
Hoses/lines must not be kinked/tensioned/bent!
Release bolts (1-3).

2007 BMW 335i
Lower front axle carrier max. 10 cm; if necessary, disconnect cooler return line/coolant pipe from front axle
carrier.
Installation:
 Bolt (1) M12x90

 Bolt (2) M12x145
 Bolt (3) M12x53
Tighten down first screws (1) and then screws (2, 3). Tightening torque, see 31 10 1AZ in 31 10 FRONT
AXLE SUSPENSION .

After installation:
FRONT STEERING .
STRUTS WITH RUBBER MOUNTS

31 12 000 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT CONTROL ARM
NOTE: If the control arm is detached from the front axle carrier, it is necessary after
reinstallation to carry out a wheel/chassis alignment check.

2007 BMW 335i
 Remove front wheel. See 10 WHEELS .

If necessary, remove jointed rod of ride-height sensor from control arm.
Fig. 30: Locating Jointed Rod Of Ride-Height Sensor

Release nut (1); if necessary, grip at Torx socket (T40).
Installation:
Keep control arm to swivel bearing connection clean and free from oil and grease.
Tightening torque, see 31 12 4AZ in 31 12 CONTROL ARMS AND STRUTS .

2007 BMW 335i
Slacken nut (1).
Remove screw towards front; if necessary remove bracket (2) with ride-height sensor.
Take off control arm.
Installation:
Screw head must point in direction of travel.
Tighten bolt connection in normal position.
Fig. 32: Identifying Nut And Bracket

After installation:
FRONT STEERING .
31 12 050 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT TRAILING LINK

2007 BMW 335i
 Remove front wheel. See WHEELS .

 Remove front underbody protection. See REMOVING AND INSTALLING / REPLACING FRONT
UNDERBODY PROTECTION.
 Release WHEEL ARCH COVER on front left and right bottom and press to one side (only
E82/E88/E92/E93).
Remove pedestrian protection (only E82/E88/E92/E93 from 03/2012): Slacken screw (1) on front pedestrian
protection. Release screws (2) from deformation element and adapter. Tightening torque 51 11 7AZ/ 8AZ .
Fig. 33: Removing Pedestrian Protection

Press deformation element (1) towards the bottom and remove adapter (2) towards the top.
Fig. 34: Press Deformation Element Toward Bottom

Release nut (1); if necessary, grip at Torx socket. Installation note: Keep tension strut to swivel bearing
connection clean and free from oil and grease. Replace self-locking nut. Tightening torque 31 12 2AZ. See 31
12 2AZ
2007 BMW 335i

Release bolt (1) and remove tension strut. Raise locking nut (2) in area of bore and detach from front axle
support. Installation note: Replace locking nut. Tighten screw connection in NORMAL POSITION .
Tightening torque 31 12 1AZ. See 31 12 2AZ
Fig. 36: Identifying Locking Nut

31 12 080 REMOVING AND INSTALLING/REPLACING BOTH TENSION STRUTS
 Remove both front wheels. See WHEELS .

 Remove front assembly underside protection. See REMOVING AND INSTALLING / REPLACING
FRONT ASSEMBLY UNDERSIDE PROTECTION .
 Release WHEEL ARCH COVER on front left and right bottom and press to one side (only
E82/E88/E92/E93)
2007 BMW 335i
Remove pedestrian protection (only E82/E88/E92/E93 from 03/2012):
Slacken screw (1) on front pedestrian protection.
Release screws (2) from deformation element and adapter.
Fig. 37: Removing Pedestrian Protection
Press deformation element (1) towards the bottom and remove adapter (2) towards the top.
Fig. 38: Press Deformation Element Toward Bottom
Release nut (1), if necessary, grip at inner Torx socket.
Installation note:
Keep tension strut to swivel bearing connection clean and free from oil and grease.
2007 BMW 335i
Release bolt (1) and remove tension strut.
Tightening torque: see 1AZ in 31 12 CONTROL ARMS AND STRUTS
Raise locking nut (2) at area of bore and pull off from front axle support.
Installation note:
Replace locking nut.
Tighten down screw connection in NORMAL POSITION .
Fig. 40: Identifying Blot And Locking Nut

31 12 134 REPLACING RUBBER MOUNT IN LEFT OR RIGHT TRAILING LINK

2007 BMW 335i
Special tools required: 31 3 031 31 3 032
IMPORTANT: Rubber mounts may only be changed once. On some models faulty rubber
mounts are replaced by hydro mounts! Procedure remains the same!
Necessary preliminary tasks: Check ball joints of trailing links while installed, replace trailing link if
necessary Remove trailing link. See REMOVING AND INSTALLING/REPLACING BOTH TENSION
STRUTS.
IMPORTANT: If the trailing link already features an identification mark with a center punch, it
is necessary to replace the trailing link. See REMOVING AND
INSTALLING/REPLACING BOTH TENSION STRUTS.
Mark trailing link with a punch mark in area (A).
Fig. 41: Identifying Tension Struts Punch Marking Area

Using a press and special tools 31 3 031 and 31 3 032 , press rubber mount out of tension strut.
NOTE: Special tool 31 3 031 must be exactly flush with rubber mount bush.
2007 BMW 335i
Fig. 42: Identifying Special Tools (31 3 031 And 31 3 032)

Installation note: Keep rubber mount and bushing in tension strut clean and free from grease. Align rubber
mount by way of arrow to marking on tension strut and press in. The deviation must not exceed ± 5°.
Fig. 43: Aligning Rubber Mount

Installation note: Protrusion (A) equally large.
Fig. 44: Identifying Protrusion

31 12 138 REPLACING RUBBER MOUNTS ON BOTH TENSION STRUTS
NOTE: Procedure is described in the document REPLACING RUBBER MOUNTS IN

TRAILING LINK LEFT OR RIGHT.
WHEEL BEARINGS AND STUB AXLE

31 21 090 REPLACING LEFT / RIGHT SWIVEL BEARING
2007 BMW 335i
 31 2 230
 Remove front brake disc. See 11 FRONT BRAKE .

 Remove front pulse generator from swivel bearing. See 34 52 525 REPLACING ONE FRONT PULSE
GENERATOR .

Slacken control arm bolt connection on front axle support in order to prevent control arm rubber mount from
being damaged.
Remove control arm from swivel bearing.
Remove tie rod end from swivel bearing. See 32 21 151 REPLACING LEFT OR RIGHT TIE ROD .
WARNING: Risk of injury! Tension strut is under tension.
Remove trailing link from swivel bearing
Support swivel bearing with workshop jack and a suitable mounting.
Release nut (1) and remove holder (2) for pulse generator and if necessary brake pad sensor.
Pull out bolt towards front.

2007 BMW 335i
Installation:
Note insertion direction of screw.
Tightening torque, see 31 31 3AZ in 31 31 SPRING STRUTS .
Fig. 46: Removing Nut And Holder

Spread swivel bearing with special tool 31 2 230.
Lower workshop jack and remove swivel bearing.
Installation:
Keep press fit of swivel gearing and spring strut in lower area clean and free from oil and grease.

2007 BMW 335i
Expand swivel bearing with special tool 31 2 230, align by way of gap to positioning pins (1) on back of spring
strut and raise as far as it will go.
Fig. 48: Identifying Special Tool 31 2 230 And Positioning Pins

Installation:
Make sure swivel bearing contacts stop (1) correctly.
Fig. 49: Identifying Bearing Contacts Stop

Replacement:
Modify or if necessary replace wheel bearing.
Modify brake carrier/brake guard plate. See 34 11 250 REMOVING AND INSTALLING / REPLACING A
BRAKE CARRIER / BRAKE GUARD PLATE AT FRONT .
After installation:
2007 BMW 335i
FRONT STEERING .
31 21 180 REMOVING AND INSTALLING/REPLACING BEARING FOR FRONT WHEEL
 Remove brake disc. See 11 FRONT BRAKE .
Release screws (1).
Press wheel bearing (2) off swivel bearing with a suitable tool and remove.
Installation:
Tightening torque, see 31 21 1AZ in 31 21 WHEEL BEARINGS AND STEERING KNUCKLE .
Fig. 50: Identifying Screw And Wheel Bearing

Installation:
When reusing, recut all the threads in the wheel bearing.
Keep contact surface (1) of swivel bearing and wheel bearing clean and free from oil and grease.
2007 BMW 335i
Fig. 51: Identifying Contact Surface Of Swivel Bearing And Wheel Bearing
SPRING STRUT
31.... LAYOUT OF SPRING STRUT SHOCK ABSORBER
2007 BMW 335i
Fig. 52: Layout Diagram Of Spring Strut Shock Absorber

Facts:
Consequence:
2007 BMW 335i
Procedure:
31 31 000 REMOVING AND INSTALLING COMPLETE LEFT OR RIGHT SPRING STRUT SHOCK
ABSORBER
IMPORTANT: If the centering pin is missing from the support bearing, the position of the
studs to the wheel arch must be marked so that the original camber is
approximately maintained.
Only one nut may ever be released for marking.
 Remove front wheel. See 10 WHEELS .

 Remove front brake disc. See 11 FRONT BRAKE .
 Remove anti-roll bar link from spring strut.
 Detach plug connection for pulse generator and expose line up to holder on spring strut
 Detach plug connection for brake pad sensor and expose line up to holder on spring strut

Slacken control arm bolt connection on front axle carrier in order to prevent control arm rubber mount from
being damaged.
2007 BMW 335i
Remove control arm from swivel bearing.
Remove tie rod end from swivel bearing. See 32 21 151 REPLACING LEFT OR RIGHT TIE ROD .
Remove trailing link from swivel bearing
WARNING: Risk of injury! Secure spring strut against falling out.
Centering pin missing: remove tension strut (on spring strut dome) and mark position of threaded pins to wheel
arch. See 51 71 371 REMOVING AND INSTALLING/REPLACING TENSION STRUT ON LEFT OR
RIGHT SPRING STRUT DOME .
Release nuts (1) and remove spring strut with swivel bearing towards bottom.
Installation:
Clean contact surface in spring strut dome.
Align spring strut using centering pin to bore in wheel arch or studs to wheel arch and push upwards.

IMPORTANT: Replace faulty sealing washer (1).

Reinstall sealing washer (1) and plate insert (2).
2007 BMW 335i
Fig. 55: Identifying Sealing Washer And Plate

After installation:
FRONT STEERING .
31 31 031 REPLACING FRONT LEFT OR RIGHT SPRING STRUT SHOCK ABSORBER
 31 2 210
 31 2 230
 31 3 341
 31 3 354
 31 3 355
 31 3 358
IMPORTANT: When replacing shock absorber/spring strut, renew auxiliary damper!
WARNING: Before using the special tool 31 3 340 take care to read through the
Owner's Handbook!
All the safety information and instructions contained in the Owner's

Handbook must be strictly observed!
2007 BMW 335i
Failure to observe these safety precautions and instructions increases

the risk of serious physical injury, damage to your health and damage to
property and equipment!
IMPORTANT: 1. Prior to each use, check the special tools for defects, modifications and
operational reliability.
4. These special tools are intended solely for the purpose of tightening and
relieving cylindrical and tapered suspension springs.
6. Impact screwdrivers may not be used!
7. Do not compress coil spring to full extent.
 Remove front spring strut.
Release nut (1), remove holder (2) and remove screw (3).
Expand swivel bearing with special tool 31 2 230 and pull off spring strut.
Installation note: Keep press fit of swivel bearing and spring strut in lower area clean and free from oil and
grease.
Screw head must point in direction of travel.
Installation:

2007 BMW 335i
Fig. 56: Identifying Nut, Holder And Bolts

Installation note:
Expand swivel bearing with special tool 31 2 230, align based on gap to positioning pin (1) on rear of spring
strut and push together to stop.
Fig. 57: Expand Swivel Bearing With Special Tool 31 2 230

Installation note:
Make sure swivel bearing contacts stop (1) correctly.

2007 BMW 335i
Fig. 58: Make Sure Swivel Bearing Contacts Stop (1) Correctly
Removing:
Clamp special tool 31 3 341 in vice.
Install insert 31 3 358 in special tool 31 3 354.
Position special tools 31 3 355 and 31 3 354 with insert 31 3 358 from above on special tool 31 3 341 until
locking pins (1) can be felt and heard to snap into place.
Check seating of special tools 31 3 355 and 31 3 354 with insert 31 3 358, correct if necessary.
Fig. 59: Identifying Special Tools In Vice

Clean coil spring to remove coarse dirt and take up with special tools 31 3 355 and 31 3 354 with insert 31 3
358.
2007 BMW 335i
Twist spring strut until end of coil spring (1) is flush with end of special tool 31 3 355.
WARNING: Special tool 31 3 354 and centering ring 31 3 358 must rest correctly on
the upper spring cup! Bottom coil of coil spring must rest completely in
recess of special tool 31 3 355!
Compress coil spring until stress on piston rod is relieved.
Fig. 60: Identifying Special Tools (31 3 355) And (31 3 354) Onto Coil Spring
Take off protective cap.
Release nut with special tool 31 2 210 (grip piston rod in the process).
Fig. 61: Identifying Special Tool (31 2 210) On Nut

Remove support bearing (1), dust sleeve and supporting ring (2).
2007 BMW 335i
Remove shock absorber with auxiliary damper, gaiter and lower spring pad sideways from tensioned coil
spring.
Fig. 62: Identifying Support Bearing And Supporting Ring

If necessary, remove auxiliary damper (1), gaiter (2) and spring pad (3) from shock absorber.
Fig. 63: Identifying Auxiliary Spring, Gaiter And Lower Spring Pad
Relieve tension on coil spring. Remove coil spring with spring cup from special tools 31 3 355, 31 3 358 and 31
3 354.
2007 BMW 335i
Fig. 64: Remove Coil Spring With Spring Cup From Special Tools
Installation:
Check spring pad (1) for damage, replace if necessary.
Attach spring cup (2) with spring pad (1) to coil spring.
Fig. 65: Identifying Upper Spring Pad And Spring Plate

NOTE: End of coil spring must be positively aligned to spring pad (1).
Take up coil spring with spring cup using special tools 31 3 355, 31 3 358 and 31 3 354. Twist coil spring until
lower end of coil spring (1) is flush with end (2) of special tool 31 3 355.
2007 BMW 335i
Fig. 66: Twist Coil Spring Until Lower End Of Coil Spring (1) Is Flush With End (2) Of Special Tool 31 3
355
WARNING: Do not compress coil spring to full extent.
Special tool 31 3 354 and centering ring 31 3 358 must rest correctly on
the upper spring cup! Bottom coil of coil spring must rest completely in
recess of special tool 31 3 355!
Tension coil spring.
Fig. 67: Ensure Special Tool 31 3 354 And Centering Ring 31 3 358 Rest
Correctly On Upper Spring Cup
Check auxiliary damper (1), gaiter (2) and spring pad (3) for damage,
replace if necessary.
NOTE: Make sure spring pad (3) is correctly seated on shock absorber.
2007 BMW 335i
Fig. 68: Make Sure Spring Pad (3) Is Correctly Seated On Shock Absorber
Insert shock absorber in tensioned coil spring. Attach support disc (2) to piston rod. Check support bearing (1)
for damage, replace if necessary. Attach dust boot and support bearing to piston rod.
Fig. 69: Identifying Support Bearing And Thrust Washer

Replace nut and tighten down with special tool 31 2 210 (grip piston rod in the process). Tightening torque, see
31 31 2AZ in 31 31 SPRING STRUTS . Fit cover cap.
2007 BMW 335i

IMPORTANT: Spring pad (1) must rest positively on spring cup (2)! Upper end of coil spring
must rest on stop of spring pad (1)!
Fig. 71: Identifying Upper Spring Pad And Spring Plate

IMPORTANT: Lower end of coil spring (2) must rest on stop of spring pad (1)
Relieve tension on coil spring. Check installation position of gaiter, correct fold if necessary.
2007 BMW 335i
Fig. 72: Identifying Coil Spring And Spring Pad

After installation: Carry out wheel alignment procedure. See 32 00 150 KDS CHASSIS/WHEEL
ALIGNMENT CHECK WITH LOAD UP TO DESIGN POSITION or 32 00 155 KDS
CHASSIS/WHEEL ALIGNMENT CHECK WITH RIDE-HEIGHT MEASUREMENT WITHOUT
LOAD . Carry out steering angle sensor adjustment / alignment for active steering.61 31 996 CARRY OUT
STEERING ANGLE SENSOR ADJUSTMENT or 32 10 005 ADJUSTMENT FOR ACTIVE FRONT
STEERING .

SPRING STRUT DOME
 00 9 120
IMPORTANT: Risk of damage! Driving without the tension strut is not permitted.
Tension strut screws must be tightened to torque and then tightened down
with special tool 00 9 120.
IMPORTANT: Risk of damage! Catch (2) and seal (3) of cover (1) must not be damaged.
Even a minimally damaged cover (1) may result in water leaking in; if
necessary, replace cover (1).
NOTE: Two possible versions of cover (1):
A. Turn cover (with notch) approx. 45° counterclockwise

B. Snap out cover (without notch) in upward direction
Remove cover (1) and release screw underneath.

2007 BMW 335i
Fig. 73: Identifying Cover, Catch And Seal

NOTE: Grommet (3) must not be pulled out of bulkhead because this eliminates the
possibility of correct feeding in when installed.
Release screw (1).
Grip grommet (3) and pull out tension strut (2) in direction of arrow.
Fig. 74: Identifying Screws, Tension Strut And Grommet

Installation:
Replace screws.
Carefully feed tension strut (1) into grommet (2).
Tighten down screws to specified torque and then retighten to angle of rotation using special tool 00 9 120.
2007 BMW 335i
Tightening torque, see 51 71 2AZ in 51 71 SEALS AND LOOSE BODY PARTS .
Fig. 75: Identifying Tension Strut And Grommet

SPRING WITH SUSPENSION

31 33 001 REMOVING AND INSTALLING FRONT LEFT OR RIGHT SPRING STRUT SUPPORT
BEARING
NOTE: Procedure is described in replacing front left or right spring strut.
Replacement:
Vehicle with spacer ring:
NOTE: Spacer ring (A) is fitted in vehicles with "rough road package" version.
Unscrew nuts.
Remove spacer ring (A) from support bearing.
Installation:
Align spacer ring (A) using centering pin (1) to support bearing and place in position.

2007 BMW 335i
Fig. 76: Identifying Adapter And Centering Pin

NOTE: If an adapter (A) without a centering pin was fitted, centering pin (1) of new
adapter (A) must be driven in.
Version without rough road package:
If necessary, drive out centering pin (1).
NOTE: If a support bearing (2) was fitted without centering pin (1), the centering pin (1)
of the new support bearing (2) must be driven or twisted out.
Fig. 77: Identifying Centering Pin And Support Bearing

31 33 095 MEASURING RIDE-LEVEL HEIGHT OF VEHICLE

2007 BMW 335i
 Move vehicle into normal position
Determine actual ride height (A) - to do so, attach tape measure to rim flange (2) at bottom middle and measure
to lower edge of wheel arch (1).
Fig. 78: Identifying Ride Height

31 33 100 REMOVING AND INSTALLING/REPLACING COIL SPRING FOR LEFT OR RIGHT

FRONT SPRING STRUT
IMPORTANT: Both coil springs on the relevant axle must be replaced only in the event of
corrosion breakage!
NOTE: Procedure is described in replacing front left or right spring strut.
STABILIZER BAR
31 35 000 REMOVING AND INSTALLING/REPLACING FRONT STABILIZER
IMPORTANT: To avoid complaints being made by the customer about noise (e.g. grating), set
the car on its wheels and tighten down the stabilizer mounting to specified
torque.
 Remove anti-roll bar link on both sides from stabilizer.
Release screws (1) and remove brackets.

2007 BMW 335i
Release nuts (2); if necessary, grip screws after repair.
Remove stabilizer (3); if necessary, press off front axle carrier with a suitable tool.
Installation:
Check rubber mount on both sides for damage, replace if necessary.
Replace self-locking nuts (do not tighten down).
Set car on its wheels and tighten down nuts to tightening torque, see 31 35 1AZ in 31 35 STABILIZER BAR .
Fig. 79: Identifying Screws, Nuts And Stabilizer

Repair solution for studs:
Release screw (1).
Raise locking nut (2) in area of bore and detach from front axle carrier.
Installation:
Replace locking nut.
Drive out studs (3) in upwards direction and remove/feed out through an opening in front axle carrier.
Insert new screws from above.

2007 BMW 335i
Fig. 80: Identifying Screws, Locking Nut And Studs

Replacement:
Remove rubber mount on both sides from stabilizer.
31 35 005 REMOVING AND INSTALLING/REPLACING PUSH ROD (ANTI-ROLL BAR LINK) FOR
LEFT/RIGHT ANTI-ROLL BAR
Release nut (1) and remove bracket for brake hose.
Release nut (3) and remove stabilizer link (2).
Installation:
Tightening torque, see 2AZ in 31 35 STABILIZER BAR .

2007 BMW 335i
Fig. 81: Identifying Nuts And Stabilizer Link

31 35 021 REPLACING RUBBER MOUNTS OF STABILIZER RETAINING FIXTURE ON FRONT

AXLE CARRIER
 Remove stabilizer from front axle carrier
Remove retaining bracket (1) and rubber mount (2) on both sides.
Installation:
Keep retaining bracket (1), rubber mount (2) and stabilizer clean and free from oil and grease.
Fig. 82: Identifying Retaining Bracket And Rubber Mount

TROUBLESHOOTING
31 90... FRONT AXLE TROUBLESHOOTING
Follow troubleshooting for steering/shock absorbers.
FRONT AXLE TROUBLESHOOTING CHART

Fault Cause Remedy
Grinding noise (louder when Wheel bearings faulty Replace wheel bearings
negotiating bends)
Vibration Wheel imbalance Balance wheels
Radial/lateral rim runout Check rims, replace if necessary
Radial tire runout Match or replace tires
2007 BMW 335i
Wheel imbalance Balance wheels

Radial/lateral rim runout Check rims, replace if necessary
Rubber mount of control arm Replace control arms
faulty
Ball joint in control arm worn Replace control arms
Rubber mount of tension strut Replace rubber mounts on both
faulty tension struts
Ball joint on tension strut worn Replace both tension struts
Excessive steering wheel Rubber mount of control arm Replace control arms
play/steering wheel inclination faulty
Rubber mount of tension strut Replace rubber mounts on both
faulty tension struts
Excessive steering wheel Bolts for reinforcement strut Tighten down bolts
play/steering wheel inclination loose
Bolt for V-strut loose Tighten down bolts
Bolts for front axle carrier to Replace bolts
engine carrier loose
Bolt for spring strut to swivel Replace bolt & nut
bearing loose
Rubber mounts for stabilizer bar Replace both rubber mounts of
bracket faulty stabilizer bar bracket
Ball joints on stabilizer link(s) Replace both stabilizer links
worn
Excessive tire wear Front or rear axle alignment Check suspension components for
incorrectly adjusted damage; if necessary, carry out
chassis/wheel alignment check
31 90... TROUBLESHOOTING SHOCK ABSORBER
Read and comply with Information on replacing shock absorbers.
SHOCK ABSORBER TROUBLESHOOTING CHART

Fault Cause Remedy
Wheel knocking (bottoming) Auxiliary spring faulty Visually inspect auxiliary spring
for cracking, replace auxiliary
spring
AWD only: Visually inspect
support ring for damage
Shock absorber leaking (oil/gas) Replace shock absorber
Rattling noise Shock absorber mounting loose Tighten shock absorber
2007 BMW 335i
Support bearing faulty/hardened Replace support bearing

Shock absorber leaking (gas/oil) Replace shock absorber
Worn down areas (flattened areas) Shock absorber leaking (gas/oil) Replace shock absorber
on tire profile
Long after-swinging of body after Shock absorber leaking Replace shock absorber
driving over rough road (insufficient shock absorber
effect)
Building-up of body in case of Shock absorber leaking Replace shock absorber
successive uneven surfaces (insufficient shock absorber
effect)
Wheels jumping even on normal Shock absorber leaking Replace shock absorber
road surfaces (insufficient shock absorber
effect)
Whistling noises Separating skin in vent holes of Remove separating skin
auxiliary spring
2007 BMW 335i
2007-08 ENGINE Fuel Supply System - 335i, 335xi Twin Turbo
2007-08 ENGINE
Fuel Supply System - 335i, 335xi Twin Turbo
00 FUEL PICK-UP, CLEANING

16 00 GENERAL FUNCTION DESCRIPTION FOR FUEL SUPPLY SYSTEMS
Fuel Supply Systems, Spark-Ignition Engines
Fuel system
The electric fuel pump in the fuel tank generates the pressure in the fuel system which is set by the pressure
regulator to a specific level.
Tank venting system
The tank venting system is an enclosed system which is vented via a carbon canister. The carbon is incorporated
in the carbon canister as granulate. The large surface of the carbon stores the fuel vapors which occur in the fuel
tank. The carbon canister must be regenerated on a regular basis so as to be able to continue storing fuel vapors.
Regeneration is performed by way of purging with fresh air via the intake manifold. This process is controlled
by the engine control unit.
16 00 005 DRAINING AND FILLING FUEL TANK
 16 1 080
IMPORTANT: Observe country-specific safety regulations.
Ensure adequate ventilation in the place of work!
Connect the exhaust and extraction systems to the exhaust tailpipe.
The electric fuel pump must not operate without fuel! After completing repairs
but before starting the engine for the first time, fill the fuel tank with min. 5 l
fuel through the fuel filler pipe.
Do not damage non-return flap when pulling out extraction hose.
Diesel vehicles:
Before starting the engine for the first time, if the tank has been run dry or drawn off, fill with diesel fuel and
turn on ignition for approx. 1 minute. The fuel circuit is thus filled and vented, which results in the engine firing
more quickly.
2007 BMW 335i
Drawing off fuel:
Start engine and allow to run.
The electric fuel pump runs.
In this way, the fuel is repumped through the suction jet pump from the left to the right side of the fuel tank.
NOTE: Fuel can be drawn out of left and right sides of tank through filler neck, leaving
only a small residue. The residual quantity is drawn off through the service
opening (on right/left).
Insert special tool 16 1 080 into filler neck. (See 16 1 080 HOSE GUIDE )
Special tool 16 1 080 has two different diameters for petrol/gasoline and diesel vehicles! (See 16 1 080 HOSE
GUIDE )
Slide extraction hose of extractor unit, refer to BMW Service Workshop Equipment and Planning
Documentation, through special tool 16 1 080 into the fuel filler pipe, turning in the process if necessary. (See
16 1 080 HOSE GUIDE )
Insertion length approx. 120 cm.
IMPORTANT: Comply with the following instruction if the extraction hose can only be
inserted approx. 100 cm before meeting resistance.

Draw off fuel as much as possible with extractor unit, refer to BMW Service Workshop Equipment and
Planning Documentation.
Follow drawing off of fuel on fuel gauge in instrument cluster.

2007 BMW 335i
NOTE: If the extraction hose meets resistance at an insertion length of approx. 100 cm,
a second person must press gently against the rubber hose of the filler pipe.
Only for US cars with N51 engines (metal filler pipe)!
The extraction hose is correctly positioned in the tank at an insertion length of

approx. 120 cm.
IMPORTANT: Watch out for escaping fuel when withdrawing the extraction hose from the
filler pipe.
Drawing off residual fuel quantity:
Fig. 2: Locating Extraction Hose

IMPORTANT: Ensure car interior is adequately ventilated.
Catch dripping fuel in a suitable container.
Remove left sensor unit. (See 16 12 001 REMOVING AND INSTALLING OR REPLACING FUEL
GAUGE SENSOR (PETROL/GASOLINE, LEFT))
Remove right sensor unit. (See 16 12 000 REMOVING AND INSTALLING OR REPLACING FUEL
GAUGE SENSOR (PETROL/GASOLINE, RIGHT))
Draw off residual fuel quantity through service openings.
NOTE: Only for US cars with N51 engines!
Fuel filling:
Insert special tool 16 1 080 into filler neck. (See 16 1 080 HOSE GUIDE )
2007 BMW 335i
Special tool 16 1 080 has two different diameters for petrol/gasoline and diesel vehicles! (See 16 1 080 HOSE
GUIDE )
Slide extraction hose of extractor unit, refer to BMW Service Workshop Equipment and Planning
Documentation, approx. 40 cm into fuel filler pipe.
Fill fuel from suction extractor unit.
Fig. 3: Inserting Special Tool (16 1 080) Into Filler Neck

Drawing off after fault in suction jet pump:
Draw off right half of tank completely through fuel filler pipe.
Remove cap from left service opening.
Insert extraction hose through service opening in tank, fuel (also residual quantity) can be drawn off.
Fig. 4: Inserting Extraction Hose Through Service Opening In Tank

2007 BMW 335i
16 00 100 CHECKING FUEL TANK AND TANK VENTILATION SYSTEM FOR LEAKS
 13 3 010
 16 1 070
 16 1 171
 16 1 174
 Remove cover for carbon canister. (See 51 71 ... REMOVING AND INSTALLING/REPLACING
COVER FOR CARBON CANISTER and/or 51 71 ... REMOVING AND
INSTALLING/REPLACING COVER FOR CARBON CANISTER
The following procedure is only applicable to vehicles without the tank leak diagnosis module.
Comply with the following conditions in order to obtain plausible test results:
 Content of fuel tank:

1. Maximum 90%
2. Minimum 13% (reserve telltale must not light up).
 Park the car in the workshop at least 2 hours before the test so that the fuel temperature is approximately
that of the workshop temperature (ideal fuel temperature approx. 10 ... 20°C).
Disconnect line to evaporation strainer (1) from carbon canister.
IMPORTANT: Risk of breakage!
Carefully remove evaporation strainer from carbon canister.
Using special tool 16 1 070, seal opening (2) for evaporation strainer on carbon canister. (See 16 1 070 PLUG
(CARBON CANISTER) )
NOTE: Cut off special tool 16 1 070 to seal opening to evaporation strainer. (See 16 1
070 PLUG (CARBON CANISTER) )
2007 BMW 335i
Fig. 5: Identifying Special Tool (16 1 070), Strainer & Seal

Remove fuel filler cap and connect special tool 16 1 174 to fuel filler neck.
Clamp special tool 16 1 174 on fuel filler neck with adjusting wheel (1).
Fig. 6: Identifying Special Tool (16 1 174) Onto Fuel Filler Neck
IMPORTANT: Turn pressure regulator on special tool 16 1 171 counterclockwise up to stop.
Connect special tool 16 1 171 using compressed air line (1) to garage compressed air system (8 ... 10 bar).
Connect pressure sensor (2) from Diagnosis and Information System with a measuring range of 0 ... 25 bar.
IMPORTANT: Do not yet connect fast-release coupling (3) of special tool 16 1 171.
2007 BMW 335i
Fig. 7: Identifying Special Tool (16 1 171), Air Line, Pressure Sensor & Fast-Release Coupling
1. Select "Measurement" function on Diagnosis and Information System (DIS).

2. Using pressure regulator on special tool 16 1 171, increase pressure by 0.20 bar.
3. Connect special tool 16 1 174 to fast-release coupling of special tool 16 1 171.
4. Wait until the value at the Diagnosis and Information System (BMW scan tool) has levelled out.
5. Using pressure regulator on special tool 16 1 171, reset gauge pressure in fuel tank to 0.20 bar.
IMPORTANT: Do not under any circumstances increase pressure by more than 0.30 bar as
this would result in damage to the fuel tank and venting system.
Using special tool 13 3 010, disconnect delivery line from special tool 16 1 171 to fuel filler neck. (See 13 3 010
HOSE CLIP )
Allow a rest period of approx. 20 sec.
Read off and note down starting pressure value.
Wait approx. 120 sec.
Read off final pressure value and compare with starting pressure value.
2007 BMW 335i

Measurement evaluation:
 Pressure drop up to 0.01 bar:
System OK
 Pressure drop over 0.02 bar:
System leaking beyond permitted levels
If the system is leaking, a leak test must be carried out and the defective components replaced.
16 00 102 CHECKING FUEL TANK AND TANK VENTING SYSTEM FOR LEAKS WITH TANK
LEAKAGE DIAGNOSIS MODULE (DMTL)
NOTE: An OBD fault is indicated by the "Check Engine" indicator lamp in the
instrument cluster lighting up.
This may indicate a leak in the tank venting system.
Information on this is provided by the fault memory of the DME control unit.
 Read out fault memory of DME control unit and carry out a diagnosis in accordance with faults stored.
 A leak test of the DMTL module is then carried out if:
 The components of the DMTL module are OK.
 A fault is stored in the DME fault memory (tank leak detected).
Adhere to following conditions in order to carry out a correct leak test:

2007 BMW 335i
 Content of fuel tank < 90%

 Reserve indicator lamp "off"
 Leave car in workshop for at least 2 hours so that fuel temperature comes into line with workshop
temperature (ideal fuel temperature approx. 10...20°C).
 Do not under any circumstances fill up car with fresh fuel (strong exhalation of fresh fuel).
 Check that tank cap is correctly seated.
WARNING: During the leak test, under no circumstances apply external

pressurization through the fuel filler neck as this may cause incorrect
readings.
In the Diagnosis and Information System (DIS), go to the "Function and component selection" (BMW scan
tool).
Work through tank leakage diagnosis module. Leakage test is carried out.
If fault is recorded again in DME fault memory (tank leak detected), carry out leak test. (See 16 00 510
CONDUCTING LEAK TEST ON FUEL TANK AND TANK VENTING SYSTEM)
16 00 510 CONDUCTING LEAK TEST ON FUEL TANK AND TANK VENTING SYSTEM
NOTE: The following procedure is only applicable to vehicles with the tank leak
diagnosis module (DMTL).
For vehicles without tank leak diagnosis module:
Pressurize fuel tank and tank venting system. (See 16 00 100 CHECKING FUEL
TANK AND TANK VENTILATION SYSTEM FOR LEAKS)
During the leak test with a leak detector, be sure to follow the operating
instructions of the equipment manufacturer.
NOTE: Select "Tank leak diagnosis module (DMTL)" on Diagnosis and Information
System (DIS).
 The leak diagnosis pump pressurizes the fuel tank and tank ventilation
system for 30 sec.
 If pressure is needed for longer than 30 sec., press "Activate" button again
after 30 sec.
IMPORTANT: On vehicles with tank leak diagnosis modules (DMTL), do not work with
external pressurization as the tank ventilation system will leak under this
2007 BMW 335i
condition.
On account of emerging fuel vapors, carry out all work in well ventilated rooms
or use a suitable extractor system.
Observe country-specific accident prevention and occupational safety

regulations.
The leak test can be carried out with a leak detector.
Possible causes may be:
 - Tank cap leaking (check tank cap pressure relief valve). (See 16 11 130 CHECKING FILLER CAP
PRESSURE RELIEF VALVE)
 - Tank venting lines leaking (fuel tank - carbon canister - tank venting valve).
 - Tank vent line leaking (engine compartment).
 - Fuel level sensor flange on tank leaking.
Fig. 9: Identifying Fuel Tank Leak Detector

11 FUEL TANK WITH MOUNTING

16 11 ... REMOVING AND INSTALLING OR REPLACING VENT HOSE FROM CARBON
CANISTER TO DUST FILTER
 Remove cover for carbon canister (See 51 71 ... REMOVING AND INSTALLING/REPLACING
 Remove rear right wheel arch cover
2007 BMW 335i
Release quick-release coupling (1) and detach vent hose.
Installation:
Quick-release coupling (1) must audibly snap into place.
Check locking of quick-release coupling by pulling, do not actuate release element in the process.
Fig. 10: Identifying Quick-Release Coupling

Carefully press vent hose out of clamps (1).
Fig. 11: Identifying Vent Hose Clamps

16 11 030 REMOVING AND INSTALLING OR REPLACING FUEL TANK (PETROL/GASOLINE)
IMPORTANT: After installation of fuel tank/prior to first engine start-up:

2007 BMW 335i
 Check ground connection at fuel filler neck to body for continuity. If

necessary, clean contact surface between body and fuel filler pipe screw
connection.
 Fill fuel tank with min. 5 l fuel.
 Check transfer function of suction jet pump. (See 16 12 ... CHECKING
REPUMPING FUNCTION OF SUCTION-JET PUMP WITH BMW DIAGNOSIS
SYSTEM)
 Draw off fuel from fuel tank (See 16 00 005 DRAINING AND FILLING FUEL TANK)
 Remove rear seat bench (See 52 26 000 REMOVING AND INSTALLING/REPLACING LEFT OR
RIGHT REAR SEAT (THROUGH-LOADING) )
 Remove guide tube for handbrake cables (See 34 41 140 REMOVING AND INSTALLING OR
REPLACING GUIDE TUBE FOR HANDBRAKE CABLES and 34 41 140 REMOVING AND
INSTALLING OR REPLACING GUIDE TUBE FOR HANDBRAKE CABLES )
 Remove right wheel arch trim (See 51 71 041 REMOVING AND INSTALLING/REPLACING
REAR LEFT OR RIGHT WHEEL ARCH COVER )
 Remove rear left and right underbody panelling
 Remove left and right underbody cover
Release screws (1) and remove cover (2) from left and right sides of fuel tank.
Fig. 12: Identifying Screws & Cover

Left sensor unit:
Press grey ring (2) towards sensor unit and pull out fuel feed line (3).
2007 BMW 335i
Fig. 13: Identifying Plug Connection, Ring & Fuel Feed Line
Right sensor unit:
Unlock quick-release fastener and detach vent line (2).
Installation:
Make sure quick-release fasteners engage correctly.
Fig. 14: Identifying Plug Connection & Vent Line

Release hose clamp (1) and detach fuel filler hose (2).
Installation:
2007 BMW 335i
Tightening torque 16 12 1AZ, see FUEL SUPPLY SYSTEM -- TORQUE SPECIFICATIONS -- TWIN
TURBO
Fig. 15: Identifying Hose Clamp & Fuel Filler Hose

Unlock quick-release fastener (1) and detach vent line (2).
Detach vent line (2) from holder (3).
Fig. 16: Identifying Quick-Release Fastener, Vent Line & Holder

Heavily support the fuel tank.

2007 BMW 335i
Fig. 17: Supporting Fuel Tank

Unfasten nut.
Installation:
Tightening torque, 16 11 1AZ, see FUEL SUPPLY SYSTEM -- TORQUE SPECIFICATIONS -- TWIN
TURBO .
Fig. 18: Locating Self-Locking Nut

Release screws for tightening straps on left and right and remove tightening straps.
Carefully lower fuel tank.
IMPORTANT: Carefully feed the vent line through the body when lowering the fuel tank.
2007 BMW 335i
Installation:
TURBO .
Fig. 19: Locating Straps On Left & Right

Installation:
Note rubber mount with spacer bush.
Wide collar on spacer bush points to screw head.
Fig. 20: Locating Rubber Mount With Spacer Bush

The following components must be modified when the fuel tank is replaced:
 Modify Vent line (1)

 Modify Right sensor unit (2) (See 16 12 000 REMOVING AND INSTALLING OR REPLACING
FUEL GAUGE SENSOR (PETROL/GASOLINE, RIGHT))
 Modify Left sensor unit (3) (See 16 12 001 REMOVING AND INSTALLING OR REPLACING
2007 BMW 335i
FUEL GAUGE SENSOR (PETROL/GASOLINE, LEFT))
Fig. 21: Identifying Vent Line, Right Sensor Unit & Left Sensor Unit
16 11 030 REMOVING AND INSTALLING/REPLACING FUEL TANK (PETROL/GASOLINE

VEHICLES WITH US VERSION DMTL)
IMPORTANT: After installation of fuel tank/prior to first engine start-up:

connection.
 Remove guide tube for handbrake cables (See 34 41 140 REMOVING AND INSTALLING OR
REPLACING GUIDE TUBE FOR HANDBRAKE CABLES and/or 34 41 140 REMOVING AND
INSTALLING OR REPLACING GUIDE TUBE FOR HANDBRAKE CABLES )
 Remove left and right ram-air lips
 Remove left and right underbody cover
 Partially detach underbody panelling
Release screws (1) and remove cover (2) from left and right sides of fuel tank.
2007 BMW 335i

Left sensor unit:
Press gray ring (2) towards sensor unit and pull out fuel feed line (3).
Right sensor unit:
Unlock quick-release fasteners and disconnect lines (2).

2007 BMW 335i
Fig. 24: Identifying Plug Connection & Lines

Release hose clamp (1) and detach fuel filler hose (2).
Installation:
TURBO .
Fig. 25: Identifying Hose Clamp & Fuel Filler Hose

Heavily support the fuel tank.

2007 BMW 335i
Fig. 26: Supporting Fuel Tank

Unfasten nut.
Installation:
Tightening torque, 16 11 1AZ see FUEL SUPPLY SYSTEM -- TORQUE SPECIFICATIONS -- TWIN
TURBO .
Fig. 27: Locating Self-Locking Nut

Release screws for tightening straps on left and right and remove tightening straps.
Installation:
Tightening torque 16 11 2AZ see FUEL SUPPLY SYSTEM -- TORQUE SPECIFICATIONS -- TWIN
2007 BMW 335i
TURBO .
IMPORTANT: Carefully feed the vent line through the body when lowering the fuel tank.
Fig. 28: Locating Straps On Left & Right

Installation:
Note rubber mount with spacer bush.
Wide collar on spacer bush points to screw head.
Fig. 29: Locating Rubber Mount With Spacer Bush

The following components must be modified when the fuel tank is replaced:
 Modify Right sensor unit (2) (See 16 12 000 REMOVING AND INSTALLING OR REPLACING
FUEL GAUGE SENSOR (PETROL/GASOLINE, RIGHT))
 Modify Left sensor unit (3) (See 16 12 001 REMOVING AND INSTALLING OR REPLACING
FUEL GAUGE SENSOR (PETROL/GASOLINE, LEFT))
2007 BMW 335i
Fig. 30: Identifying Vent Line, Right Sensor Unit & Left Sensor Unit
16 11 048 REMOVING AND INSTALLING OR REPLACING FUEL FILTER WITH PRESSURE

REGULATOR (PETROL/GASOLINE)
 16 1 020
IMPORTANT: Ensure adequate ventilation in the place of work!
Ensure absolute cleanliness when working on the open fuel tank.
Contaminants in the fuel tank can impair driving operation or may even result
in vehicle breakdown!
 Remove right sensor unit (See 16 12 000 REMOVING AND INSTALLING OR REPLACING FUEL
Release screws (1) and remove cover (2) from left side of fuel tank.
2007 BMW 335i

Press grey ring (1) towards sensor unit and detach fuel feed line (3).
IMPORTANT: Do not use any tools to release the quick-release fasteners.
Release screw cap with special tool 16 1 020 and remove service cap. (See 16 1 020 PIN WRENCH )
Installation:
TURBO .
2007 BMW 335i
Fig. 33: Identifying Special Tool (16 1 020) Onto Service Cap
IMPORTANT: After tightening to specified torque, notch (1) on screw cap (2) must be in area
(A)!
NOTE: Illustration shows the tank removed.
Fig. 34: Identifying Notch & Screw Cap

Installation:
Service cap can only be installed in one position.
When installing, make sure lug (1) of service cap engages in corresponding opening (2) on fuel tank.
Make sure that the lever sensor moves freely before fitting the service cap.
2007 BMW 335i
Clean sealing faces and install new seal.
Fig. 35: Identifying Lug Of Service Cap

Attach an auxiliary lead (1) to hose pack (2) through service opening.
The auxiliary lead is pulled through with the hose pack towards the left and facilitates subsequent reinstallation.
Fig. 36: Identifying Auxiliary Lead & Hose Pack

Carefully lift sensor unit (1) out of tank.
In so doing, press tab (2) against spring force in order to make it easier to feed sensor unit out of tank.

2007 BMW 335i
Fig. 37: Identifying Sensor Unit & Tab

Remove fuel filter (1) and hose pack (2) with auxiliary cable to left.
Installation:
When replacing the fuel filter, modify the end of the auxiliary lead to the new hose pack and carefully pull in
through the tank.
Fig. 38: Identifying Fuel Filter & Hose Pack

16 11 060 REMOVING AND INSTALLING OR REPLACING FUEL FILLER PIPE
2007 BMW 335i
 Remove rear right wheel arch trim (See 51 71 041 REMOVING AND INSTALLING/REPLACING
REAR LEFT OR RIGHT WHEEL ARCH COVER )
 Lower rear axle (See 33 31 503 LOWERING/RAISING REAR AXLE CARRIER and 33 31 503
LOWERING/RAISING REAR AXLE CARRIER )
Unhook retaining strap (1) from tank flap.
Open cap and set to one side.
Fig. 39: Identifying Retaining Strap

Installation:
Replace hose clip.
TURBO .
2007 BMW 335i
Fig. 40: Identifying Hose Clip

Unlock quick-release fastener (1) and detach vent hose (2).
Unscrew nut (3).
Fig. 41: Identifying Quick-Release Fastener, Detach Vent Hose & Nut
Unscrew nuts (1).
Installation:
TURBO .
Withdraw fuel filler pipe (2) completely out of rubber gaiter at wheel arch and feed out.
Installation:
2007 BMW 335i
Make sure rubber gaiter is correctly seated.
Fig. 42: Identifying Nut & Fuel Filler Pipe

Installation:
Clean contact surface on body and grounding lead on fuel filler pipe.
Ground connection must be guaranteed.
16 11 071 REPLACING RUBBER SLEEVE BETWEEN FUEL FILLER PIPE AND FUEL TANK
IMPORTANT: Before starting the engine for the first time:

connection.
Loosen hose clamps (1).
Detach rubber sleeve first from fuel filler pipe and then from fuel tank.
Installation:
TURBO .
2007 BMW 335i
Fig. 43: Identifying Hose Clamps

16 11 130 CHECKING FILLER CAP PRESSURE RELIEF VALVE
 13 3 010
 16 1 171
 16 1 172
Set pressure regulator on special tool 16 1 171 fully in "-" direction.
Connect special tool 16 1 171 via compressed air line (1) to workshop/garage compressed air system (8 ... 10
bar).
Connect pressure sensor (2) from Diagnosis and Information System.
Fig. 44: Identifying Special Tool (16 1 171), Air Line, Pressure Sensor & Fast-Release Coupling
2007 BMW 335i
Connect special tool 16 1 172 to fast-release coupling of special tool 16 1 171.
Install fuel tank cap on special tool 16 1 172 (3).
Fig. 45: Identifying Special Tool (16 1 172) & Special Tool (16 1 171)
NOTE: Only the absolute pressure is indicated in the display of the Diagnosis and
Information System (DIS). The current ambient air pressure is already displayed
without additional pressurization.
Check testing equipment for leaks!
Select "Measurement/Pressure" function on Diagnosis and Information System (DIS).
Increase pressure by 0.2 bar with pressure regulator on special tool 16 1 171.
Using special tool 13 3 010, disconnect supply line from special tool 16 1 171. (See 13 3 010 HOSE CLIP
and/or 13 3 010 HOSE CLIP )
Read off and note down pressure.
Wait 60 secs.
Read off pressure again and compare with starting pressure value.
CAUTION: MEASUREMENT EVALUATION TABLE

Pressure drop > 0.012 Testing equipment leaking.
bar Check connection points for
leaks.
2007 BMW 335i
Check filler cap pressure relief!
Select "Measurement/Pressure" function on Diagnosis and Information System (DIS).
Increase pressure by 0.3 bar with pressure regulator on special tool 16 1 171.
Using special tool 13 3 010, disconnect supply line from special tool 16 1 171. (See 13 3 010 HOSE CLIP
and/or 13 3 010 HOSE CLIP )
Read off and note down pressure.
Wait 60 secs.
Read off pressure value again and compare with starting pressure value.
MEASUREMENT EVALUATION TABLE

Filler cap pressure relief valve faulty.
Pressure drop > 0.012 bar
Replace fuel tank cap.
12 FUEL TRANSFER, SENSOR

16 12 ... CHECKING REPUMPING FUNCTION OF SUCTION-JET PUMP WITH BMW DIAGNOSIS
SYSTEM
Catch escaping fuel in a suitable container.
 Fill level must be < or = 28 l

 If necessary, draw off fuel from fuel tank (See 16 00 005 DRAINING AND FILLING FUEL
TANK)
 Pour two to three litres of fuel into the left tank chamber via the flange opening
 Path:
 Brief test KOMBI Instrument cluster
 Diagnosis control unit functions

2007 BMW 335i
 Diagnosis requests
 Tank sensor 1, tank sensor 2
NOTE: Tank sensor 1 = right tank sensor
Tank sensor 2 = left tank sensor
Start engine.
Compare display for left and right tank chambers.
Repumping function OK
If fill level of tank sensor 2 (left chamber) is falling (approx. one litre per minute).
Repumping function not OK
If fill level of tank sensor 2 (left chamber) is stable or rising.
16 12 000 REMOVING AND INSTALLING OR REPLACING FUEL GAUGE SENSOR

(PETROL/GASOLINE, RIGHT)
 16 1 020
 Draw off fuel from fuel tank

Release screws (1) and remove cover (2) from right side of fuel tank.
2007 BMW 335i

Unlock and detach vent line (2).
If necessary, remove fuel line for independent heating.

Installation:
Procedure for tightening screw cap, see next work step.

2007 BMW 335i
IMPORTANT: Fit screw cap without using a tool and tighten hand-tight.
Then tighten screw cap with special tool 16 1 020 until notch (1) points to
marking (2). (See 16 1 020 PIN WRENCH )
Fig. 49: Identifying Notch & Marking Points Of Screw Cap

Carefully raise service cap (1).
Installation:
2007 BMW 335i
Clean sealing faces and install new seal (3).
Locating rods (4) must fit correctly in the hole of the delivery unit.
Fig. 50: Identifying Service Cap, Vent Line, Seal & Rods
Installation:

Unclip black return lines (1) from bracket.

2007 BMW 335i
Unlock and disconnect quick-release fastener (2) of fuel line.
IMPORTANT: Do not use any tools to release the fuel feed line.
Draw off remaining fuel from surge chamber.
Carefully lift fuel pump with fuel level sensor (3) out of fuel tank.
If necessary, turn fuel pump 90° counterclockwise and tilt towards lever sensor.
Fig. 52: Identifying Black Return Lines, Quick-Release Fastener & Fuel Level Sensor
Removing fuel level sensor:
Carefully unlock tabs (1) and pull off fuel level sensor upwards in direction of arrow.
Disengage line (2) from holders.
Unlock plug connection (3) and detach from service cap.
Installation:
Fuel level sensor and cable connector must audibly snap into place!
IMPORTANT: Risk of damage:
Carefully feed cable out of cable guide.
Do not kink cable.

2007 BMW 335i
Fig. 53: Identifying Tabs, Line & Plug Connection

16 12 001 REMOVING AND INSTALLING OR REPLACING FUEL GAUGE SENSOR

(PETROL/GASOLINE, LEFT)
 16 1 020
 Remove right sensor unit (See 16 12 000 REMOVING AND INSTALLING OR REPLACING FUEL
Release screws (1) and remove cover (2) from left side of fuel tank.
2007 BMW 335i

Press grey ring (2) towards sensor unit and pull out fuel feed line (3) straight.
After installing fuel feed line, carry out tensile test and leak test.
Installation:

2007 BMW 335i

Installation:
2007 BMW 335i
Clean sealing faces and install new seal.

Attach an auxiliary lead (1) to hose pack (2) through service opening.
The auxiliary lead is pulled through with the hose pack towards the left and facilitates subsequent reinstallation.
Installation:
Make sure when pulling through the hose pack that the tank ventilation system in the tank tunnel is not
damaged.
Fig. 59: Identifying Auxiliary Lead & Hose Pack

Carefully lift sensor unit (1) out of tank.

2007 BMW 335i
In so doing, press tab (2) against spring force in order to make it easier to feed sensor unit out of tank.
Fig. 60: Identifying Sensor Unit & Tab

Remove sensor unit (1) and hose pack (2) with auxiliary cable to left.
Installation:
When replacing the sensor unit, modify the end of the auxiliary lead to the new hose pack and carefully pull in
through the tank.
Fig. 61: Identifying Sensor Unit & Hose Pack

2007 BMW 335i
16 12 010 REMOVING AND INSTALLING OR REPLACING CARBON CANISTER
Unlock quick-release fasteners (1) and disconnect vent lines.
Release screws (2) and remove carbon canister (3).
Installation:
TURBO .
Fig. 62: Identifying Quick-Release Fasteners, Screws & Carbon Canister

16 12 010 REMOVING AND INSTALLING/REPLACING CARBON CANISTER (WITH TANK

LEAKAGE DIAGNOSIS MODULE N54)
 If necessary, press exhaust system heat shield to one side slightly
Unlock and detach quick-connect couplings (2).

2007 BMW 335i
Release screws (3) and remove carbon canister with tank leakage diagnosis module.
Installation:
TURBO .
Fig. 63: Identifying Plug Connection, Quick-Connect Couplings & Screws

13 FUEL VENTILATION
16 13 015 REMOVING AND INSTALLING/REPLACING TANK LEAK DIAGNOSIS MODULE
(PETROL/GASOLINE CARS WITH US DMTL VERSION)
 Remove carbon canister (See 16 12 010 REMOVING AND INSTALLING OR REPLACING

CARBON CANISTER)
Release screws (1).
Installation:
TURBO .
Disconnect tank leak diagnosis module (2) from carbon canister in direction of arrow.
Installation:

2007 BMW 335i
Fig. 64: Identifying Screws & Tank Leak Diagnosis Module

14 FUEL PUMP
16 14 010 REMOVING AND INSTALLING OR REPLACING FUEL PUMP (PETROL/GASOLINE)
 16 1 020
 Draw off fuel from fuel tank (See 16 00 005 DRAINING AND FILLING FUEL TANK and/or 16 00
005 DRAINING AND FILLING FUEL TANK )
2007 BMW 335i

If necessary, remove fuel line for independent heating.

Installation:

2007 BMW 335i

Carefully raise service cap (1).
Installation:
2007 BMW 335i
Clean sealing faces and install new seal (3).
Locating rods (4) must fit correctly in the hole of the delivery unit.
Fig. 69: Identifying Service Cap, Vent Line, Seal & Rods
Installation:

Unclip black return lines (1) from bracket.

2007 BMW 335i
Unlock and disconnect quick-release fastener (2) of fuel line.
Draw off remaining fuel from surge chamber.
Carefully lift fuel pump with fuel level sensor (3) out of fuel tank. If necessary, turn fuel pump 90°
counterclockwise and tilt towards lever sensor.
Fig. 71: Identifying Black Return Lines, Quick-Release Fastener & Fuel Level Sensor
16 14 060 REMOVING AND INSTALLING/REPLACING DUST FILTER FOR TANK LEAK

DIAGNOSIS MODULE (DMTL)
 Remove rear left wheel arch trim (See 51 71 041 REMOVING AND INSTALLING/REPLACING
REAR LEFT OR RIGHT WHEEL ARCH COVER and/or 51 71 041 REMOVING AND
INSTALLING/REPLACING REAR LEFT OR RIGHT WHEEL ARCH COVER )
Unlock and disconnect quick-connect coupling (1).
Release screws (2) and remove dust filter (3).
Installation:
Tightening torque: 16 13 3AZ, see FUEL SUPPLY SYSTEM -- TORQUE SPECIFICATIONS -- TWIN
TURBO .
2007 BMW 335i
Fig. 72: Identifying Quick-Connect Coupling, Screws & Dust Filter

16 14 500 REMOVING AND INSTALLING OR REPLACING CONTROL UNIT FOR ELECTRIC

FUEL PUMP
DISCHARGE) and/or 61 35 ... NOTES ON ESD PROTECTION (ELECTRO STATIC
DISCHARGE) )
 E81, E87, E91 and E92:
Remove backrest side section for right rear seat (See 52 26 008 REMOVING AND
INSTALLING/REPLACING LEFT OR RIGHT SIDE SECTION ON REAR SEAT BACKREST
and/or 52 26 008 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT SIDE
SECTION ON REAR SEAT BACKREST )
 E90:
Remove backrest
Release nuts (2) and remove control unit (3).
Installation:
TURBO .
2007 BMW 335i
Fig. 73: Identifying Plug Connection, Nuts & Control Unit

Replacement:

2007 BMW 335i
2007-08 ENGINE Fuel System - 335i, 335xi (N54, N53) Twin Turbo
2007-08 ENGINE
Fuel System - 335i, 335xi (N54, N53) Twin Turbo
31 FUEL PUMP WITH DRIVE

13 31 ... NOTES ON FUEL PRESSURE CHECK (REFERENCE PRESSURE: ENVIRONMENT)
Feature of this version with ambient pressure:
The connection for the vacuum hose of the fuel pressure regulator is located between the throttle and the air
cleaner or on the air cleaner.
Test precondition:
The correct fuel pressure regulator is fitted.
 Using the EPC, check whether the fuel pressure regulator suitable for the car is fitted:
Connect test adapter.
Description of operation:
The control function of the fuel pressure regulator must be guaranteed under all operating conditions. The fuel
pump must always be able to generate a higher fuel pressure than the pressure regulated by the pressure
regulator.
The injection rate is adjusted by means of the injection time; the injection time is controlled by the DME.
Description of operation: fuel return line
When the engine is at a standstill and the ignition key is in position 0, the fuel return line after the pressure
regulator is at zero pressure.
Description of operation: pressure retaining function
The pressure regulator closes when the engine is at a standstill and the ignition key is in position 0. The fuel
pressure in the delivery line is retained over an extended period. A non-return valve closes in the fuel pump.
These measures help to retain the fuel pressure in the fuel system. Extended starting times are thus avoided.
Complaint: drive characteristic faults, lack of power
 Run engine at idle speed and measure fuel pressure.
If the measured value is less than the nominal value - 0.2 bar:
 Line cross-sections in fuel feed are constricted or fuel filter is clogged,

2007 BMW 335i
or
 Fuel pump voltage supply is not O.K.: e.g. as a result of high contact resistance (corrosion) in plug
connection between wiring harness and fuel pump.
If the measured value is greater than the nominal value + 0.2 bar:
 Turn off engine stop and then observe measured value.

 If measured value drops to nominal value, then line cross-sections in fuel return are constricted or
clogged.
 Check the fuel lines for kinks.
If no kinks are visible:
 Replace return lines
If measured value remains too high, then pressure regulator is in all probability faulty.
IMPORTANT: With less likelihood, the return line may be completely blocked. When the
pressure regulator is removed, fuel could escape under pressure!
 Have a cleaning cloth ready and catch and dispose of escaping fuel.
 Replace the return line but not the pressure regulator.
Complaint: starting problems
 Run engine briefly at idle speed and switch off.

 Note down measured value while engine is stopped.
 Read off measured value again after approx. 20 to 30 minutes while engine is stopped.
Special tool 13 3 010 (hose clamp) is required for the following test. See 13 3 010 HOSE CLIP
If the measured value has dropped by more than 0.5 bar:
 Start engine and wait briefly for a stable pressure increase.

 Switch off the engine and immediately pinch off the delivery line just before the pressure gauge with the
special tool 13 3 010. See 13 3 010 HOSE CLIP
 Note down measured value
 Read off measured value again after approx. 20 to 30 minutes while engine is stopped
If the measured value has now dropped by less than 0.5 bar, the following faults can be present:
 Fault in delivery lines

 Fault in in-tank delivery hose
2007 BMW 335i
 Faulty pressure-holding non-return valve in fuel pump
Check components. Replace faulty components.
If the measured value has dropped by more than 0.5 bar again:
 Replace pressure regulator
NOTE:  All the fuel hoses and hose clips which were detached within the
framework of the checks must be replaced.
 Interrogate fault memory of DME control unit. Check stored fault
messages. Rectify faults. Now clear the fault memory.
51 INJ. PUMP, REGULATOR

13 51 017 REMOVING AND INSTALLING OR REPLACING HIGH-PRESSURE FUEL PUMP (N54,
N53)
 11 8 610
 13 5 020
 13 5 281
 13 5 282
 32 1 270
WARNING: Observe warning on cylinder head cover.
Disconnect battery negative terminal (risk of fire due to short-circuiting

on removal). (See 61 20 900 DISCONNECTING AND CONNECTING
BATTERY NEGATIVE LEAD and/or 61 20 900 DISCONNECTING AND
CONNECTING BATTERY NEGATIVE LEAD )
below 40°C.
IMPORTANT: Wear full face guard and protective gloves.
Fuel can emerge spontaneously at high velocity when the high-pressure line is
released!

2007 BMW 335i
Recycling:
N53 only:
Lay exhaust gas recirculation (1) upwards to one side. Do not remove.
Fig. 1: Identifying Exhaust Gas Recirculation


2007 BMW 335i


Unscrew nut (1).
Release screw (2).
Installation:
 Replace aluminum screw.

2007 BMW 335i
Fig. 4: Identifying Feed Line, Nut & Screw

Seal feed line with matching plug from special tool kit 32 1 270. See 32 1 270 PLUGS (SET)

WARNING: Wear full face guard and protective gloves.
Unscrew nut (1).
Slacken nut (2).
Unscrew bolt (3).
Disconnect high-pressure line (4).
Seal connections of high-pressure line (4) with matching plugs from special tool kit 32 1 270. See 32 1 270
PLUGS (SET)
2007 BMW 335i
Fig. 6: Identifying High-Pressure Line, Bolt & Nut

Seal fuel line connections of high-pressure pump (1) with matching plugs from special tool kit 32 1 270. See 32
1 270 PLUGS (SET)

Release screws with special tool 11 8 610. See 11 8 610 WRENCH SOCKET, HEXAGON SOCKET WAF
5
Detach high-pressure pump (1) and remove.
Engine oil can escape when pump is detached; have a cleaning cloth ready.
2007 BMW 335i

Installing high-pressure pump:
Installation of high-pressure pump is described separately from removal.
Replace sealing ring (1).
Clean contact faces.
Fig. 9: Identifying Sealing Ring

When installing, turn high-pressure pump (1) if necessary in direction of arrow until bores for screws are flush.
2007 BMW 335i
Fig. 10: Turning High-Pressure Pump

IMPORTANT: Tighten screws of high-pressure pump (1) with special tool 11 8 610 hand-tight
only. See 11 8 610 WRENCH SOCKET, HEXAGON SOCKET WAF 5
It must still be possible to turn the high-pressure pump at the flange!
This prevents twisting when high-pressure line (4) (Fig. 12) is tightened.
Pre-install high-pressure line (4).
In so doing, tighten screw connections (Fig. 12) hand-tight only (it must still be
possible to move the high-pressure line at the holder).
Only when high-pressure pump (1) has if necessary turned into position and is
thus pre-installed without twisting with high pressure-line (4) should screws of
high-pressure pump (1) be tightened down with special tool 11 8 610. See 11 8
610 WRENCH SOCKET, HEXAGON SOCKET WAF 5
Tightening torque 13 51 1AZ. See 13 51 INJECTION PUMP, CONTROL RECEPTACLE

2007 BMW 335i

IMPORTANT: Follow sequence of screw connections:
1. Tighten down nut (1) with special tool 13 5 020. Tightening torque 13 53
7AZ. See 13 5 020 WRENCH WAF 17 and 13 53 FUEL INJECTION
NOZZLES AND PIPES
2. Tighten nut (2). Tightening torque 13 53 7AZ. See 13 53 FUEL INJECTION
NOZZLES AND PIPES
3. Tighten down screw (3) for holder. Tightening torque 13 53 2AZ. See 13 53
FUEL INJECTION NOZZLES AND PIPES

Install feed line (3).
In so doing, tighten screw connection hand-tight only
6AZ. See 13 5 020 WRENCH WAF 17 and 13 53 FUEL INJECTION
NOZZLES AND PIPES
2. Tighten screw (2). Replace aluminum screw. Tightening torque 13 53 9AZ.
See 13 53 FUEL INJECTION NOZZLES AND PIPES
2007 BMW 335i

Assemble engine.
Check fuel system for leaks.
53 INJECTION NOZZLE AND LINES

13 53 158 REMOVING AND INSTALLING/REPLACING HIGH-PRESSURE RAIL (N54, N53)
 37 1 151

below 40°C.
released!
2007 BMW 335i

IMPORTANT: When working on the oil, coolant or fuel circuit, you must protect the alternator
against contamination.
 Remove pressure lines

 N54 only: Remove intake filter housing
Recycling:
Pull connector holder off high-pressure rail.
Remove all holders for wiring harness from high-pressure rail.

2007 BMW 335i
Fig. 14: Identifying Connector Holder Off High-Pressure Rail & Plug
Slacken nut (2).
Release screws (3) and remove high-pressure rail (4).
Fig. 15: Identifying High-Pressure Rail, Plug & Nut (1 Of 2)

Installing high-pressure rail:
Installation of high-pressure rail is described separately from removal.
Install high-pressure rail (4); in so doing, tighten screws (3) and nut (2) hand-tight only.
NOTE:  It must still be possible for the high-pressure rail to slide on the cylinder
head.
 Nut (2) must be able to be screwed on easily by hand.
2007 BMW 335i
Fig. 16: Identifying High-Pressure Rail, Plug & Nut (2 Of 2)

Push on plug for high-pressure sensor (1).
Fitting pressure lines:
(Same procedure for all pressure lines)
Connect pressure line (1), tightening nuts hand-tight only in the process.
IMPORTANT: Connect pressure line (1) without tension only.
To ensure distortion-free installation of the pressure line and to avoid

damaging the thread, it must be possible for both nuts to be screwed on easily
by hand!
If the nuts cannot be easily screwed on by hand, the injector must be turned
into the installation position.
Fig. 17: Identifying Pressure Line

2007 BMW 335i
NOTE: Description of "Turning injector into installation location" in the following work
step.
Only if one injector has to be turned into installation position:
 Release screw a few turns until holding-down element (1) is slackened.

 Turn injector (2) in direction of arrow until nuts on pressure line can be easily screwed on by hand.
 To do so, engage wrench on hexagon head of injector (2) if necessary.
 Tighten nuts on pressure line hand-tight.
Fig. 18: Identifying Hexagon Head Of Injector & Holding-Down Element

IMPORTANT: Do not under any circumstances pull injector out of bore!
If the injector is pulled out of the bore hole, the PTFE sealing ring must be
replaced!
Replacing PTFE sealing ring, refer to 13 53 310.
Tightening torque 13 53 1AZ. See 13 53 FUEL INJECTION NOZZLES AND PIPES
Tighten nut (2).

2007 BMW 335i
Fig. 19: Identifying PTFE Sealing Ring, Screw & Nut

Tighten down screw for holding-down element (1).
NOTE: This work step is only necessary if one of the holding-down elements has been
slackened before hand.
Fig. 20: Locating Holding-Down Element

Adhere to tightening sequence:
 First tighten down nut (1) on injector.

 Then tighten down nut (2) on high-pressure rail.
When tightening nut (1) on injector, grip hexagon head of injector with wrench (3).
Tighten down nuts with special tool 37 1 151.

2007 BMW 335i

Assemble engine.
13 53 192 REMOVING AND INSTALLING OR REPLACING A HIGH-PRESSURE LINE (N54, N53)
 32 1 270
 37 1 151

below 40°C.
Fuel can emerge spontaneously at high velocity when the high-pressure

line is released!
2007 BMW 335i

 Remove ignition coil
NOTE:  Ignition coils must not be fouled by fuel! It is therefore essential to protect
the spark plug slot against ingress of fuel with a cloth!
 Make sure the spark plug slot is absolutely clean.
 Ignition coils heavily fouled by fuel must be replaced (check by smelling).
Recycling:
NOTE: The following description applies to all pressure lines.
Release nuts (1), gripping the injector with a wrench (2) in so doing.
Disconnect pressure line (3).
IMPORTANT: If several pressure lines are removed, ensure that each pressure line is
reinstalled in its original location (cylinder).
Mark pressure lines.

2007 BMW 335i
Fig. 22: Identifying Pressure Line, Injector With Wrench & Nuts
Fuel can emerge spontaneously at high velocity from the fuel injectors!
To reduce the fuel pressure, place rag over fuel injector and carefully tap
against the fuel injector with a spanner.
There is a risk of injury if the fuel pressure is not reduced!
Close off injector with protective cap (1).
Protective caps are available from BMW Parts Service.
Seal high-pressure rail with a matching plug from special tool kit 32 1 270. See 32 1 270 PLUGS (SET)
Fig. 23: Identifying Special Tool (32 1 270) (1 Of 2)

2007 BMW 335i
Seal pressure line (1) with a matching plug from special tool kit 32 1 270. See 32 1 270 PLUGS (SET)

Installing pressure line:
Installation of pressure rail is described separately from removal.
Same procedure for all pressure lines.

by hand!
If the nuts cannot be easily screwed on by hand, the injector must be turned
into the installation position!
2007 BMW 335i

NOTE: Description of "Turning injector into installation position" in the following two
work steps.
Only if injector has to be turned into installation position:
 Release screw a few turns until holding-down element (1) is slackened.

 Turn injector (2) in direction of arrow until nuts on pressure line can be easily screwed on by hand.
 To do so, engage wrench on hexagon head of injector if necessary.
 Tighten nuts on pressure line hand-tight.

IMPORTANT: Do not under any circumstances pull injector out of bore!
If the injector is pulled out of the bore hole, the PTFE sealing ring must be
replaced! Replacing PTFE sealing ring, refer to 13 53 310.
Tighten down screw for holding-down element (1).

2007 BMW 335i



Assemble engine.

2007 BMW 335i
13 53 310 REMOVING AND INSTALLING OR REPLACING AN INJECTOR (N54, N53)
 13 0 180
 13 0 191
 13 0 192
 13 0 193
 13 0 194
 13 0 195
 13 5 250
 37 1 151

on removal).
below 40°C.
Fuel can emerge spontaneously at high velocity from the fuel injectors!
To reduce the fuel pressure, place rag over fuel injector and carefully tap
against the fuel injector with a spanner.
There is a risk of injury if the fuel pressure is not reduced!
IMPORTANT: The tightening sequences and tightening torques of the screw connections
must be adhered to when reassembling!
Disregard of these requirements may result in leaks!

2007 BMW 335i

IMPORTANT: Injectors are not waterproof!
Carry out engine cleaning/washing only with ignition coil cover fitted.
 Remove a pressure line
NOTE: The following description applies to all injectors.
Release screw and remove holding-down element (2).
Remove injector (3).
NOTE: If several injectors are removed, ensure that each injector is reinstalled in its
original location (cylinder).
Mark injectors.
Fig. 29: Locating Holding-Down Element, Plug & Screw

Procedure in event of stuck injector:
Mount special tool 13 0 180 on injector (1). See 13 0 180 DRIVE-OUT TOOL
2007 BMW 335i

Mount special tool 13 5 250. See 13 5 250 EXTRACTOR
Carefully knock out injector (1) with special tools 13 0 180 and 13 5 250. See 13 0 180 DRIVE-OUT TOOL
and 13 5 250 EXTRACTOR
Fig. 31: Identifying Special Tools (13 0 180) & (13 5 250)
After removing, fit protective caps (1 and 3) to injector tip and fuel line connection.
Protective caps are available from BMW Parts Service.

2007 BMW 335i
Fig. 32: Identifying Injector Tip & Fuel Line Connection

Installation:
When reusing fuel injector:
 Replace uncoupling element (2).

 Replace PTFE sealing ring (1).
A PTFE seal which has been heated once by engine operation must be replaced before the fuel injector is
reinstalled.
Fig. 33: Identifying PTFE Sealing Ring & Element

Installation:
When installing a new injector:
 Use a new uncoupling element (2).

2007 BMW 335i
 Remove protective cap (1) from injector tip max. 10 min. before installation (PTFE sealing ring swells
up).
Fig. 34: Identifying Injector Tip & Fuel Line Connection

Replacing PTFE sealing ring:
Before replacing PTFE sealing ring (1), make sure hands and work surface are clean and free of oil.
Avoid mechanical contact with injector tip (2).
Fig. 35: Identifying PTFE Sealing Ring, Protective Tape & Element
Remove PTFE sealing ring (1) with special tool 13 0 191 from injector (2).
Use a fluff-free cloth only to remove combustion residues from cylindrical part of injector tip (do not use
ultrasound or other tools/agents).
Do not clean injector tip.

2007 BMW 335i

Slide new PTFE sealing ring (1) onto mounting taper 13 0 195.

Use fingers and mounting taper 13 0 195 to slide PTFE sealing ring (1) onto injector (2).
NOTE:  Do not use fingernails to slide PTFE sealing ring on.

 Do not use any lubricating agents.
 The sealing ring is expanded when slid on.
2007 BMW 335i

To bring the expanded PTFE sealing ring to its installation dimension, slide three mounting sleeves with
decreasing diameters onto the injector.
Slide mounting sleeve (1) with large opening first onto injector (1).
Do not use any lubricating agents.
Fig. 39: Identifying Mounting Sleeves & Injector

First slide mounting sleeve 13 0 192 (large diameter) onto injector (1).
Then slide mounting sleeve 13 0 193 (medium diameter) onto injector (1).
2007 BMW 335i
Fig. 40: Identifying Special Tool (13 0 192/13 0 193)

Finally, press injector (1) into mounting sleeve 13 0 194 (small diameter).
Installation:
Install injector within 10 minutes or slide on protective cap (Fig. 34) (PTFE sealing ring swells up).

Installing injector:
Installation of injector is described separately from removal.
Before installing injector in engines that have been run:
 Clean contact surfaces of uncoupling elements (2) in cylinder head.

 Clean injector bore: To do so, preferably slide injector without uncoupling element (2) but with new
PTFE sealing ring (1) in and out of injector bores several times.
2007 BMW 335i
The PTFE sealing ring must then be replaced.
 Replace uncoupling element (2).
Fig. 42: Identifying PTFE Sealing Ring & Element

IMPORTANT: Injector adjustment!
An injector adjustment must be carried out if an injector is replaced or changed on the cylinder side.
Injector adjustment is carried out with the aid of a so-called adjustment value.
The adjustment value is printed in two blocks of three digits on the injector.
The adjustment value must be read off before installation!
Fig. 43: Locating Adjustment Value (1 Of 2)

Enter the adjustment value according to the installation position (cylinder) of the injector.
2007 BMW 335i
If injector adjustment is not carried out, the engine may run roughly or fail to start.
Description of injector adjustment at end of instruction.

Installing injector:
Install injector (3).
Install holding-down element (2).
IMPORTANT: Tighten screw hand-tight only so that holding-down element (2) is slack and if
necessary injector can still be turned.
Fig. 45: Locating Holding-Down Element, Plug & Screw

Connect contact plug (1).

2007 BMW 335i
NOTE: Make sure holding-down element (1) is correctly seated.


by hand!
If the nuts cannot be screwed on easily by hand, the injector must if necessary
be turned a little.

Turn injector (2) if necessary in direction of arrow until nuts on pressure line can be easily screwed on by hand.
2007 BMW 335i
Tighten nuts on pressure line hand-tight.
Then tighten down screw for holding-down element (1).



2007 BMW 335i
Carrying out injector adjustment:
 Connect DIS Tester

 Identify car
 Select "Function selection"
 Select "Service functions"
 Select "Engine electronics"
 Select "Adjustment programs"
 Select "Adjust injectors"
 Change "Test schedule"
 For each replaced injector, the adjustment value must be entered according to the installation position
(cylinder).


Assemble engine.
2007 BMW 335i
13 53 332 REMOVING AND INSTALLING/REPLACING FEED LINE (N54, N53)
 13 5 020
 13 5 281
 13 5 282
 32 1 270

on removal).
below 40°C.
Wear protective goggles.

Recycling:

2007 BMW 335i
N53 only:



2007 BMW 335i
Unscrew nut (1).
Release screw (2).

Close off feed line and high-pressure pump with a matching plug from special tool kit 32 1 270. See 32 1 270
PLUGS (SET)
2007 BMW 335i

Installation:
Install feed line (3).
In so doing, tighten screw connection hand-tight only
6AZ. See 13 53 FUEL INJECTION NOZZLES AND PIPES and 13 5 020
WRENCH WAF 17
2. Tighten screw (2). Replace aluminum screw. Tightening torque 13 53 9AZ.
See 13 53 FUEL INJECTION NOZZLES AND PIPES

Assemble engine.
2007 BMW 335i
13 53 334 REMOVING AND INSTALLING/REPLACING PRESSURE LINE (N54, N53)
 11 8 610
 13 5 020
 32 1 270

on removal).
below 40°C.
released!

Recycling:

2007 BMW 335i
Release nuts (1 and 2).
Unscrew bolt (3).
Disconnect high-pressure line (4).
Seal connections of high-pressure line (4) with matching plugs from special tool kit 32 1 270. See 32 1 270
PLUGS (SET)

Seal fuel line connection of high-pressure pump (1) and high-pressure rail with matching plugs from special
tool kit 32 1 270. See 32 1 270 PLUGS (SET)

2007 BMW 335i
Installing pressure line:
Installation of pressure rail is described separately from removal.
Install delivery line (4).
In so doing, tighten screw connections (1 to 3) hand-tight only.

damaging the thread, it must be possible for both nuts (1 and 2) to be screwed
on easily by hand!
If the nuts cannot be screwed on easily by hand, the high-pressure pump must
be slackened.
This operation is described in the following section.

Only if high-pressure pump has to be slackened:
Slacken screws with special tool 11 8 610. See 11 8 610 WRENCH SOCKET, HEXAGON SOCKET WAF
5
Turn high-pressure pump (1) on flange so that nuts of high pressure line can be easily screwed on by hand.
Tighten down screws. Tightening torque 13 51 1AZ. See 13 53 FUEL INJECTION NOZZLES AND PIPES
2007 BMW 335i

1. Tighten down nut (1) with special tool 13 5 020. See 13 5 020 WRENCH
WAF 17 . Tightening torque 13 53 7AZ. See 13 53 FUEL INJECTION
NOZZLES AND PIPES
2. Tighten nut (2). Tightening torque 13 53 7AZ. See 13 53 FUEL INJECTION
NOZZLES AND PIPES
3. Tighten down screw (3) for holder. Tightening torque 13 53 2AZ. See 13 53
FUEL INJECTION NOZZLES AND PIPES

Assemble engine.

2007 BMW 335i
13 53 594 REPLACING LOW-PRESSURE FUEL SENSOR (N54, N53)
 32 1 270

on removal).
below 40°C.
Wear protective goggles.

Recycling:
N53 only:
2007 BMW 335i

Release low-pressure sensor (2).
IMPORTANT: When releasing and tightening down sensor, grip at width across flats of low-
pressure line (3).
NOTE: Seal low-pressure line (3) if necessary with a matching plug from special tool kit
32 1 270. See 32 1 270 PLUGS (SET)
Fig. 64: Identifying Low-Pressure Sensor & Plug

Assemble engine.

2007 BMW 335i
13 53 596 REPLACING HIGH-PRESSURE FUEL SENSOR (N54, N53)
 32 1 270
 32 2 100

on removal).
below 40°C.
released!

Recycling:

2007 BMW 335i
54 THROTTLE AND OPERATION

11 61 368 REPLACING CHARGE-AIR DUCT (N54)

 Remove intake filter housing
grease!
Unfasten clip.
Tightening torque 13 71 6AZ. See 13 71 AIR INTAKE SILENCER
Installation:
Install charge-air hoses dry and free from grease.
Detach charge-air hose (1) from charge-air duct (2).
Fig. 65: Identifying Charge-Air Hose From Charge-Air Duct

Release quick-connect couplings (1) by turning lock through 90°.
Detach recirculated air hoses (2) and lay to one side.

2007 BMW 335i
Fig. 66: Identifying Quick-Connect Couplings & Recirculated Air Hoses

Installation:
Pay attention to markings.
Recirculated air hoses must audibly snap into place.
Fig. 67: Identifying Bring Lock


2007 BMW 335i
Fig. 68: Identifying Plug

Pressure pipes cannot be fitted without antiseize agent!
Release screw.
Unlock quick-connect coupling (1).
Detach charge-air duct (2) from throttle valve assembly and remove.
Fig. 69: Identifying Quick-Connect Coupling & Charge-Air Duct

Installation:
Coat sealing ring of quick-connect coupling with antiseize agent.

2007 BMW 335i
Charge-air duct (2) must snap audibly into place.
Assemble engine.
Read out fault memory of DME control unit
11 61 365 REPLACING FRONT CHARGE-AIR DUCT (N54)
 11 8 670
 Remove fan cowl

Pressure pipes with quick-connect couplings cannot be fitted without antiseize

agent.
Unlock quick-connect coupling.
Detach charge-air duct (1) from intercooler (2).
Installation:
 Coat sealing rings of quick-connect couplings with antiseize agent.

 Pressure pipes must audibly snap into place.
Fig. 70: Identifying Charge-Air Duct From Intercooler

2007 BMW 335i
IMPORTANT: Risk of damage! to sealing rings.
Special tool 11 8 670 is essential. See 11 8 670 PLIERS
Attach charge-air duct (1) with special tool 11 8 670 to intercooler (2). See 11 8 670 PLIERS
Installation:
Texts refer to Fig. 71 shown on right side.
The procedure is identical for the left side.

grease!
Unfasten clip.
Detach front charge-air duct (1) from charge-air duct (2).
Feed out front charge-air duct (1) towards top and remove.
Installation:
Install charge-air hose (charge-air duct) dry and free from grease.
2007 BMW 335i
Fig. 72: Identifying Front Charge-Air Duct From Charge-Air Duct

11 61 362 REPLACING RIGHT CHARGE-AIR DUCT (N54)
 11 8 670
 Remove coolant expansion tank

Pressure pipes cannot be fitted without antiseize agent.
Mark vacuum hoses (1) and detach.
Unfasten bolts and nuts.
Tightening torque bolt 11 65 6AZ. See 11 65 TURBOCHARGER AND CONTROL
Raise bracket (2) slightly.
Mark vacuum hoses on underside and detach.
Remove bracket (2).

2007 BMW 335i
Fig. 73: Locating Vacuum Hoses & Bracket

Release nuts and remove heat shield.
Fig. 74: Locating Heat Shield & Nut

Release clamp and detach charge-air duct (1).

2007 BMW 335i
Fig. 75: Locating Charge-Air Duct & Clamp

Release clamp and detach charge-air duct (1).
Fig. 76: Locating Charge-Air Duct

Installation:
Check O-rings and replace if necessary.
Prior to fitting, coat O-ring with suitable antiseize agent.

2007 BMW 335i
Fig. 77: Identifying O-rings

Unlock quick-connect coupling.
Detach charge-air duct (2) from intercooler (3) and remove.
Fig. 78: Locating Charge-Air Duct From Intercooler

IMPORTANT: Risk of damage! to sealing rings!
Special tool 11 8 670 is essential. See 11 8 670 PLIERS
Attach charge-air duct (1) with special tool 11 8 670 to intercooler. See 11 8 670 PLIERS
Installation:
 Coat sealing rings of quick-connect couplings with antiseize agent.

2007 BMW 335i
 Pressure pipes must audibly snap into place.

Assemble engine.
Check DME (turbocharger) for correct operation.
13 54 030 REMOVING AND INSTALLING/SEALING THROTTLE VALVE ASSEMBLY (N54)
protection).

 Remove charge-air duct
Unlock and disconnect line (1).
Release screws.
Tightening torque 13 54 1AZ. See 13 54 THROTTLE AND ACTUATOR
Remove throttle assembly (3).

2007 BMW 335i
Fig. 80: Locating Connector Screws

Installation:
Replace sealing ring (1) of throttle assembly (2).
Fig. 81: Identifying Sealing Ring Of Throttle Assembly

Installation:
Check stored fault messages.
62 SENSOR FOR CONTROL UNIT

13 62 531 REPLACING COOLANT TEMPERATURE SENSOR (N54)

2007 BMW 335i
Recycling
Catch and dispose of escaping oil and coolant.

 Remove fan cowl
NOTE: Coolant temperature sensor is mounted on cylinder head at front.
Release screw.
Tightening torque 17 21 1AZ. See COOLING SYSTEM - TIGHTENING TORQUES - SEDAN .
Disconnect oil line (1).
Catch and dispose of emerging fluid.
Fig. 82: Locating Oil Line

Installation:

2007 BMW 335i
Fig. 83: Locating Sealing Rings

Release temperature sensor (2).
Installation:
Tightening torque 13 62 1AZ. See 13 62 SENDERS FOR CONTROL UNIT
If necessary, top up coolant.
Check cooling system for leaks.
Fig. 84: Identifying Temperature Sensor & Plug

NOTE: After completion of work, check engine oil level.
Check stored fault messages.

2007 BMW 335i
71 INTAKE SILENCER
13 71 000 REMOVING AND INSTALLING/REPLACING INTAKE FILTER HOUSING (N54)
E82, E90, E91, E92, E93 only:

 Remove intake duct
E60, E61 only:
Lift out expansion rivet (1).
Unclip air duct (2) from intake filter housing and remove.
Fig. 85: Identifying Intake Filter Housing & Expansion Rivet

Release clamp and detach air intake hose.
Unclip line (1) from air filter housing.

2007 BMW 335i
Fig. 86: Locating Air Filter Housing

Release clamp and detach air intake hose.
Pull off wiring harness holders (1) in upward direction.
Detach intake filter housing (2) from bearings pins of rubber mounts in upward direction and remove.
Installation:
Make sure intake filter housing rubber mounts are correctly seated on bearing pins.
Fig. 87: Identifying Intake Filter Housing & Expansion Rivet

13 71 160 REMOVING AND INSTALLING/REPLACING FRONT AIR DUCT (N54)

2007 BMW 335i
 Remove fan cowl

 Drain coolant
Unlock and remove coolant hose (1).
Release quick-connect coupling (2) by turning lock and detach.
Release hose clamp and detach air duct (3).
Fig. 88: Identifying Coolant Hose, Quick-Connect Coupling & Air Duct
Installation:
Turn lock (1) back until arrow markings are flush.
Push air hose onto air duct.
Air hose must audibly snap into place.

2007 BMW 335i

Release bolts and detach coolant hose (1).
Installation:
Check sealing ring, replace if necessary.
Release screws (2).
Fig. 90: Identifying Coolant Hose & Screw

Unclip line (1).
Release coolant hose (2) from holder (4), unlock and remove.
Release coolant hose (3) from holder (4) and lay downwards to one side.
2007 BMW 335i
Fig. 91: Identifying Coolant Hose & Holder

Detach air duct (1) in direction of arrow.
NOTE: Illustration with engine removed.
Fig. 92: Identifying Air Duct

Installation:
Check sealing ring (1) for damage and replace if necessary.
Make sure sealing ring (1) is correctly seated in air duct (2).
2007 BMW 335i
Fig. 93: Identifying Sealing Ring & Air Duct

13 71 170 AIR DUCT, REAR (N54)
 Remove intake air manifold (See 11 61 050 REMOVING AND INSTALLING INTAKE AIR
MANIFOLD (N54) )
 Remove transmission (See
Release quick-connect coupling (3) by turning lock and detach.
Fig. 94: Identifying Quick-Connect Coupling With Turning Lock & Detach
Installation:
2007 BMW 335i
Turn lock (1) until arrow markings are flush.

Release screw (1).
Release screw (2) and remove bracket (3).
Fig. 96: Identifying Bracket & Screw

Pull off air duct (1), feed out and remove.

2007 BMW 335i
Fig. 97: Locating Air Duct

Installation:
Check sealing ring (1) for damage and replace if necessary.
Make sure sealing ring (1) is correctly seated in air duct (2).
Fig. 98: Identifying Sealing Ring & Air Duct

72 AIR CLEANER
13 72 001 REPLACING AIR CLEANER ELEMENT (N54)
Open retainers.
Open upper section (1) of intake filter housing and remove.

2007 BMW 335i
Fig. 99: Locating Intake Filter Housing & Retainers

Remove air cleaner element (1).
Installation:
Clean upper and lower sections of intake filter housing from inside.
Install new air cleaner element.
Fig. 100: Identifying Air Cleaner Element

90 CARBON CANISTER VENTILATION

13 90 500 REPLACING TANK VENT VALVE (N54)
 Check stored fault messages

2007 BMW 335i

 Remove intake filter housing (See 13 71 000 REMOVING AND INSTALLING/REPLACING
INTAKE FILTER HOUSING (N54))
Installation location:
The tank vent valve is located at the rear below the intake air manifold.
Unlock hose (2) and detach.
Unlock hose (3) on throttle valve assembly and disconnect.
Detach tank vent valve (4) from holder and remove.
Fig. 101: Identifying Throttle Valve Assembly, Plug & Hose

NOTE: Read out fault memory of DME control unit.

2007 BMW 335i
TRANSMISSION Gear Shift Mechanism - Repair Instructions
TRANSMISSION
Gear Shift Mechanism - Repair Instructions
CENTER SHIFT, MANUAL

25 11... OVERVIEW OF GEARSHIFT MECHANISM FOR MANUAL TRANSMISSION
Fig. 1: Identifying Gear Shift Mechanism Components Location

25 11... REPLACING U-TYPE BELLOWS

2007 BMW 335i
 Remove Shift Lever

 Remove Vibration Damper (if fitted).
Detach U-gaiter from shift lever.
If necessary, rub inside of molded section (1) beforehand with Circolight.
Fig. 2: U-Gaiter Molded Section And Removal Direction

Installation:
 Degrease shift lever (1)

 Coat inside of molded section (2) with Circolight
 Pull U-gaiter from above over shift lever and align
 Arrow on upper lip (3) must point crossways to mount eye (5) in direction of travel
Key:
1. Shift lever
2. U-gaiter molded section
3. U-gaiter lip
4. U-gaiter bead
5. Mount eye
2007 BMW 335i
Fig. 3: Shift Lever, U-Gaiter Molded Section, U-Gaiter Bead, U-Gaiter Upper Lip And Mount Eye
25 11... REPLACING SHIFT ROD
 Remove rear assembly underside protection

Detach locking clip.
Fig. 4: Removing Locking Clip

Pull shift rod (1) out of shift rod joint (2).
Installation:
Grease shift rod pin (3).

2007 BMW 335i
Fig. 5: Pulling Shift Rod Out Of Shift Rod Joint

Remove selector rod (2).
Installation:
Grease selector rod pin.
Fig. 6: Identifying Locking Clip And Selector Rod

25 11 000 REMOVING AND INSTALLING GEARSHIFT LEVER
 25 1 120
2007 BMW 335i
 Remove reinforcement carrier.

 Remove rear Underbody Protection.
 Remove Knob for shift lever.
 Remove gaiter for shift lever cover.
If necessary
Support transmission with workshop jack.
Remove screws and nuts.
Remove cross-member.
For tightening torque refer to 1AZ/2AZ in 23 71 TRANSMISSION MOUNTS .
Fig. 7: Cross-Member And Mounting Screws

Remove Shift Rod (2).
Installation:
Grease shift rod pin.
Key:
1. Retainer
2. Shift rod
2007 BMW 335i
Fig. 8: Shift Rod, Retainer And Component Location

IMPORTANT: New retaining clips fitted as from 04.08.
Retaining clip must interlock captively with retaining web (1) behind gearshift
rod pin.
Fig. 9: Identifying Retaining Web

Insert special tool 25 1 120 into mount and turn 90° counterclockwise.
Press mount upwards out of shift arm.

2007 BMW 335i
Fig. 10: Special Tool (25 1 120) And Removal Direction

Feed U-gaiter from shift arm and out of body cutout.
Lift out shift lever.
Installation:
Pull U-gaiter from below completely over shift arm receptacle.
Fig. 11: Shift Arm And U-Gaiter

Installation:
Pull U-gaiter bead (4) over receptacle on shift arm and pop U-gaiter lips (3) into body cutout.
Make sure the arrow on the upper U-gaiter lip (3) is seated in the direction of travel and crossways to the shift
lever eye (5).
2007 BMW 335i
Key:
1. Shift lever
2. U-gaiter molded section
3. U-gaiter lips
4. U-gaiter bead
5. Shift lever eye
Fig. 12: Shift Lever, U-Gaiter Molded Section, U-Gaiter Bead, U-Gaiter Lips And Shift Lever Eye
Installation:
GREASE shift lever ball.
Fit mount on shift arm receptacle.
Align retaining lugs of mount to openings in receptacle (crossways to direction of travel).
Press shift arm with mount downwards until mount snaps audibly into place (if necessary, use a pressing-in
tool).
2007 BMW 335i
Fig. 13: Pressing Shift Arm With Mount Downwards Until Mount Snaps
25 11 000 REMOVING AND INSTALLING GEARSHIFT LEVER (AWD)
 Remove UNDERBODY PROTECTION .

 Remove center muffler (N53 only)
 Remove EXHAUST SYSTEM .
 Remove TRANSMISSION CROSSMEMBER .
 Release CENTER MOUNT .
 Remove SHIFT LEVER COVER.
If necessary, remove sound insulation (1).
Fig. 14: Identifying Soundproofing

2007 BMW 335i
Lift off retainer (1).
Installation:
Grease shift rod pin.
Grease, refer to OPERATING FLUIDS .
Fig. 15: Identifying Selector Rod And Retainer

Retaining clip must interlock captively with retaining web (1) behind shift rod
pin.

Insert special tool 25 1 120 in mounting and turn 90° counterclockwise.

2007 BMW 335i
Press mount upwards out of shift arm.
Fig. 17: Turning Special Tool 25 1 120 Counter-Clockwise 90°

Remove rubber gaiter from body cutout and lift out with selector lever.
Fig. 18: Identifying Rubber Gaiter From Body

Installation:
Insert rubber gaiter with arrow in direction of travel towards front.

2007 BMW 335i
Fig. 19: Locating Rubber Gaiter

Installation:
Grease selector lever ball.
Grease, refer to OPERATING FLUIDS .
Install selector lever in selector arm.
Align mount:
 Arrows on mount in longitudinal axis of vehicle.

 Retaining lugs of mount, transverse to direction of travel.
Fig. 20: Locating Selector Lever In Selector Arm

Installation:
Press mount in area of retaining lugs into selector arm until it audibly snaps into place.
2007 BMW 335i
Fig. 21: Pressing Retaining Lugs Into Selector Arm

Installation:
Pull inner rubber gaiter over bowl on selector arm and press outer rubber gaiter into body cutout.
Fig. 22: Pressing Outer Rubber Gaiter Into Body Cutout

25 11 001 REPLACING COMPLETE GEARSHIFT LEVER
 Remove Selector Lever.

 Remove Vibration Damper (if fitted).
Detach mount from selector lever.
Installation:
Grease ball joint.

2007 BMW 335i
Grease, refer to BMW Service Operating Fluids.
Fig. 23: Detaching Mount From Selector Lever

Detach rubber gaiter from selector lever.
Fig. 24: Detaching Rubber Gaiter From Selector Lever

Installation:
Degrease selector lever (1).
Coat rubber bellows on inside of shaped section (2) with Circolight.
Pull rubber gaiter from above over selector lever and align.
Arrow (3) on rubber gaiter must point in direction of travel (A).

2007 BMW 335i
Fig. 25: Selector Lever, U-Gaiter Shaped Section, Arrow on Gaiter And Installation Direction
25 11 041 REPLACING BALL SOCKET FOR GEARSHIFT LEVER
 Remove Shift Lever
Detach mount from selector lever.
Installation:
Grease ball joint.
Fig. 26: Detaching Mount From Selector Lever

25 11 071 REPLACING KNOB FOR SHIFT LEVER
WARNING: As from 03/07 there are two different versions. Version 2 can give rise to
2007 BMW 335i
damage if incorrectly removed.
Version 1: Shift lever knob and shift lever cover separate.
Version 2: Shift lever knob and shift lever cover are a single part.
Version 1 (shift lever knob and shift lever cover separate):
Press installation frame of gaiter (1) together a little and remove gaiter from center console.
IMPORTANT: Start removing at front left, otherwise the frame may be damaged.
Fig. 27: Gaiter And Removal Direction

NOTE: Do not twist shift lever knob during removal as this would cause the turning
lock in the knob to shear off.
Tug firmly to remove knob.
Installation:
Fit shift lever knob on shift lever, align and press on until it snaps noticeably into place.
2007 BMW 335i
Fig. 28: Knob Removal Direction

Installation:
Push gaiter (1) down until groove (2) is fully exposed.
Fig. 29: Gaiter, Groove And Installation Direction

Version 2 (shift lever knob and shift lever one single part):
Press installation frame of gaiter (1) together a little and remove gaiter from center console.
IMPORTANT: Start removing at front left, otherwise the frame may be damaged.
2007 BMW 335i
Fig. 30: Gaiter And Removal Direction

NOTE: Do not twist knob during removal as this would cause the turning lock in the
knob to shear off.
Tug firmly to remove knob.
Installation:
Fit knob on shift lever, align and press on until it snaps noticeably into place.
Fig. 31: Knob Removal Direction

25 11 081 REPLACING GAITER (SHIFT LEVER COVER) FOR SHIFT LEVER
IMPORTANT: There are 2 different versions.
Removal of shift lever cover is described in Removing Shift Lever Knob

2007 BMW 335i
 Remove Shift Lever Knob.
Installation:
Retaining lugs must not be damaged.
Fig. 32: Gaiter Retaining Lugs

25 11 101 REPLACING SHIFT ROD
 Remove rear assembly underside protection

 Remove reinforcement carrier on underbody
 Remove exhaust system (M3 only)
 Remove transfer case (AWD)
 Remove transmission cross-member.
 Remove transmission support block (M3 only)
Detach locking clip.

2007 BMW 335i
Fig. 33: Detaching Locking Clip

Retaining clip must interlock captively with retaining web (1) behind shift rod
pin.

Pull shift rod (1) out of shift rod joint (2).
Installation:
Grease shift rod pin (3).

2007 BMW 335i
Fig. 35: Pulling Shift Rod Out Of Shift Rod Joint

Installation:
Grease selector rod pin.
Fig. 36: Shift Rod, Retainer And Component Location

25 11 111 REPLACING SHIFT ROD JOINT
 Release propeller shaft at transmission and center mount.

2007 BMW 335i
Tie propeller shaft to one side.
Tasks are described in Removing Propeller Shaft.
 Remove transfer case (AWD)
Lift off retainer (1).
Disconnect shift rod (2).
Installation:
Grease shift rod.
Grease, refer to BMW Service Operating Fluids. .
Make sure shims (3) are in correct position.
Fig. 37: Retainer, Shift Rod, Shims And Removal Directions

Retaining clip must interlock captively with retaining web (1) behind gearshift
rod pin.
2007 BMW 335i

Lever spring washer (1) out of groove and push a little towards rear.
Press dowel pin (2) upwards/downwards out of shift rod joint and remove shift rod joint.
Installation:
Grease ball of selector shaft.
Replace spring washer (1).
Fig. 39: Spring Washer, Dowel Pin And Removal Direction

Installation:
Check rubber ring (1) in shift rod joint (2) and replace if necessary.
2007 BMW 335i
Fig. 40: Rubber Ring And Shift Rod Joint

25 11 211 REPLACING SHIFT ARM FOR SHIFT-LEVER MOUNT
 Remove Shift Lever

 Remove transfer case (AWD)
Lever support bearing (1) out of fixture.
Fig. 41: Support Bearing And Removal Direction

Installation:
Install support bearing (1) with arrow (2) facing upwards in holder.
2007 BMW 335i
Fig. 42: Support Bearing, Arrow And Installation Direction

Unlock bearing pin (1) in direction of arrow and remove.
Installation:
Grease bearing pin.
Fig. 43: Bearing Pin And Removal Direction

Remove shift arm.
Detach support bearing (1) from shift arm.
Installation:
Grease bearing journal.

2007 BMW 335i
Attach support bearing (1) with opening (3) towards rear on shift arm.
Fig. 44: Support Bearing And Opening

Replace bearing bush if damaged.
Press out bearing bush.
Coat new bearing bush with Circolight and then press into shift arm until side flanges of bearing bush protrude
uniformly.
Fig. 45: Bearing Bush

25 11 235 REPLACING BEARING BUSHES FOR GEARSHIFT ARM
 Remove Shift Arm

 Press out bearing bush (1).
2007 BMW 335i
 Coat new bearing bush with Circolight.

 Then press into shift arm until side surface of bush protrudes uniformly.
NOTE: Illustration shows: shift arm simply supported.
Fig. 46: Bearing Bush

25 11 245 REPLACING SHIFT ARM SUPPORT BEARING
 If necessary, remove reinforcement carrier.

 Remove rear Underbody Protection. .
 If necessary, release middle heat shield, do not remove.
NOTE: Only if heat shield has to be released.
Release nut (1) and remove bracket from rear differential.
Slide heat shield towards rear.

2007 BMW 335i
Fig. 47: Nut

Lever support bearing (1) with a short screwdriver out of mounting.
Pull support off shift arm.
Fig. 48: Support Bearing, Screwdriver And Removal Direction

Installation:
Grease bearing pin of shift arm.
Fit support bearing (1) with opening (2) towards top rear onto mounting.
2007 BMW 335i
Fig. 49: Support Bearing, Opening And Installation Direction

25 11 250 REMOVING AND INSTALLING/REPLACING VIBRATION DAMPER
 Remove shift lever cover.

 Remove Shift Lever Knob.
Open clamp (1) on vibration damper with pliers.
Unlock vibration damper with screwdriver (2) (there is a locking notch on one side only).
Lift out vibration damper.
Fig. 50: Clamp, Screwdriver And Pliers

Installation:
2007 BMW 335i
In the case of a new vibration damper which has been attachment to the shift lever, only the retainer (1) still
needs to be unlocked.
Make sure the vibration damper is correctly engaged in the shift lever.
Fig. 51: New Vibration Damper Retainer And Removal Direction

CENTER SHIFT, AUTOMATIC

25 16 056 REMOVING AND INSTALLING OR REPLACING GEARSHIFT BRACKET
(STEPTRONIC)
 Remove rear Underbody Protection. .

 Remove center console.
Version 1:
Grip clamping sleeve (1) and slacken nut (2).
Installation:
Adjust (A5S 360R / 390R, A4S 200R, 6HP26Z/19Z) or (GA6L45R) selector lever.
2007 BMW 335i
Fig. 52: Clamping Sleeve And Nut

Detach retainer (3) downwards using a screwdriver.
Fig. 53: Clamping Sleeve, Slacken Nut And Retainer

Version 2:
For tightening torque refer to 25 16 1AZ in 25 16 SHIFT CONSOLE - AUTOMATIC TRANSMISSION .
Remove clamp (2).
2007 BMW 335i
Fig. 54: Shift Cable Head, Screw And Clamp

Installation:
Adjust (A5S 360R / 390R, A4S 200R, 6HP26Z/19Z) or (GA6L45R) selector lever.
Version 3:
Release nut and disengage cable (1).
Installation:
Unfasten nut.
Adjust cable by means of holder (2) until spacing A = 1 mm is obtained
Tighten nut.
Release screws (1).
For tightening torque refer to 25 16 3AZ in 25 16 SHIFT CONSOLE - AUTOMATIC TRANSMISSION .
Remove cables from holders.
Lift shift tower out of center console.

2007 BMW 335i
Fig. 55: Shift Tower Plug Connections And Screws

25 16 056 REMOVING AND INSTALLING OR REPLACING SHIFT TOWER (AWD)

(STEPTRONIC)
 Remove REAR UNDERBODY PROTECTION .

 Remove CENTER CONSOLE .
Release screw (1).
Tightening torque: see 2AZ in 25 16 SHIFT CONSOLE - AUTOMATIC TRANSMISSION .
Remove clamp (2).
Installation:
Adjust SELECTOR LEVER

2007 BMW 335i
Fig. 56: Identifying Screw, Clamp And Cable Head

Release screws (1).
Tightening torque: see 3AZ in 25 16 SHIFT CONSOLE - AUTOMATIC TRANSMISSION .
Feed sleeve (2) out of body.
Lift shift tower out of center console.
Fig. 57: Identifying Sleeve And Screws

Installation:
Seal must not be damaged.

2007 BMW 335i

25 16 061 REPLACING GRIP/KNOB FOR SHIFT LEVER
NOTE: The method for removing the grip/knob is identical for manual and automatic
transmissions.
Do not twist grip/knob when removing as the turning lock in the knob will shear
off.
Pull off grip/knob with a firm tug in direction of arrow.
Installation:
Fit grip/knob on shift lever, align and press on until it can be felt to snap into place.
Fig. 59: Shift Lever Knob Removal Direction

25 16 065 REPLACING GAITER (SELECTOR LEVER COVER) FOR SHIFT TOWER

2007 BMW 335i
 Remove Grip
1. Carefully pull gaiter taut on leather

2. Gently press frame inwards until catch is released
3. Lift out gaiter
Fig. 60: Gaiter Removal Directions

IMPORTANT: Start removing at top left, otherwise the frame will be damaged.
Installation:
Retaining lugs must not be damaged.
Fig. 61: Gaiter Retaining Lugs

2007 BMW 335i
ACCESSORIES AND EQUIPMENT General electrical system - Repair Instructions
General electrical system - Repair Instructions
TROUBLESHOOTING
61 00... BATTERY
NOTE: Important notes and instructions for handling batteries in the dealership can be
found in:
 Battery master document

 Disconnecting Battery
 Battery Charging
 Welding Work
 External Jump-Starting Aid
Battery care and maintenance
In low-maintenance batteries, check the acid level at least once a year. If necessary, top up with distilled water
up to the top marking.
The increasing number of electronic control units in the car reduces the self-discharging time of the battery
(even in standby mode). To maintain the battery service life and to avoid exhaustive discharging, recharge laid-
up vehicles every 6 weeks at the latest. The time for self-discharging depends on vehicle type and equipment
specification.
Battery test
The battery acid density can be used to measure the charge state. However this test produces uncertainty caused
by a design-related range of variation. The acid density e.g. for a charged battery is 1.28 kg/l (in the tropical
version the acid density is 1.23 kg/l).
Another interference factor is the acid lamination immediately after filling with distilled water.
Battery wear with partially sulfated and/or heavily contaminated plates will also lead to incorrect acid density
test results.
61 00... DIAGNOSIS FOR CONDITION BASED SERVICE
NOTE: Red symbol for pre-delivery check
The vehicle is coded at the end of the assembly line so that the red symbol for the pre-delivery check is shown
in the Next Service display (same symbol as vehicle check).
2007 BMW 335i
The symbol is a reminder to the Service staff that the pre-delivery check has not yet been carried out on this car.
NOTE: Do not carry out a reset.
Do not confuse this function with the "Vehicle check" maintenance scope.
Do not carry out a reset via the instrument cluster.
When carrying out the pre-delivery check with the "Transport Mode/Pre-delivery check" service function:
The symbol is automatically removed from the display after the service function has been executed.
Fig. 1: Red Symbol For Pre-Delivery Check Screen Display

2007 BMW 335i
Fig. 2: Diagnosis Function Screen Display

4 service functions are available in the BMW diagnosis system for maintenance:
 Transport Mode/Pre-delivery check

 CBS Correction Tester Data
 Reset CBS
 CBS Correction Vehicle Data
Service function: Transport Mode/Pre-delivery check
To be able to hand over a vehicle to the customer in proper working order, it is essential to execute the
"Transport Mode/Pre-delivery check" service function.
The following items are worked through during the pre-delivery check:
 Deactivation of transport mode.

 An adaptation process must be activated in order to determine the vehicle-specific mileage/kilometrage
per week. Transport and immobilization periods before the vehicle is delivered to the customer therefore
have no effect on the customer-specific weekly mileage/kilometrage.
2007 BMW 335i
The weekly mileage/kilometrage is used to control escalation from "green" to "yellow" (approx. 4 weeks
before "red") for maintenance scopes with remaining distances. The averaged mileage/kilometrage of the
last 6 weeks is taken in to account here.
 Coding or blanking out of the legally prescribed intervals for the statutory vehicle inspection and
statutory exhaust emissions test.
 Input of the target dates for the statutory vehicle inspection and the statutory exhaust emissions test
(automatic or manual).
Automatic: By input of the date of first registration and of the time interval
Manual: By direct input of the target date
 Entry of local, service-related phone numbers, depending on vehicle equipment specification (e.g. BMW
Group Mobile Service, BMW Hotline, customer's home dealer).
The country-specific phone numbers are displayed in the BMW diagnosis system as a reference text. The
phone numbers can simply be read off during the input prompt.
 Reference to initialization of TeleService, depending on vehicle equipment specification.

 Checking and if necessary setting of the on-board date for the vehicle.
 Entry of the date for first registration of the vehicle.
 Now clear the fault memory.
NOTE: Reducing input expenditure.
Standardized data are stored in the BMW diagnosis system (for repeated use) in
the interests of minimizing the time spent on making inputs in the
garage/workshop. The standardized data can be changed with the "CBS
Correction Tester Data" service function.
Service function: CBS Correction Tester Data
Data are automatically stored in the vehicle with the "Pre-delivery check" service function.
The standardized data can be changed with the "CBS Correction Tester Data" service function.
The following standardized data can be changed:
 Phone numbers:
 BMW Group Mobile Service
 BMW Hotline
 Customer's home dealer
The country-specific phone numbers are contained as reference texts in the BMW diagnosis system (read
2007 BMW 335i
off during the input prompt). The phone numbers must be input with the international dialling code.
 Legally prescribed vehicle inspection (country-specific):

 Coding or blanking out
 Interval for calculating the target date
The target date is calculated on the basis of the date of first registration.
 Legally prescribed exhaust emissions test (country-specific):

 Coding or blanking out
 Interval for calculating the target date
The target date is calculated on the basis of the date of first registration.
NOTE: Automatic function after installation of the BMW diagnosis system.
The standardized data are automatically established when the pre-delivery check is carried out for the first time.
It is therefore not necessary to input the data separately.
Service function: Reset CBS Condition Based Service
A maintenance scope can be reset with the "Reset CBS Condition Based Service" service function. Even when
availability is over 80 %.
The benefit of reset via the BMW diagnosis system is that the on-board date is corrected automatically.
The individual maintenance scopes are displayed in the BMW diagnosis system with service counter and
availability.
 The service counter is reset by one counter on resetting. All service counters are set to "1" on new
vehicles.
The service counters are used in the Service Acceptance/Reception Module (SAM) on a scope-specific
basis for controlling additional work.
 Availability is set to 100 % on resetting. Availability in % is the wear value of the maintenance scope.
The greater the availability, the longer it is to the next maintenance scope.
0 % means that the maintenance measure must be carried out.
Service function: CBS Correction Vehicle Data
IMPORTANT: The data are overwritten.

2007 BMW 335i
Once this service function has been executed, it is no longer possible to reconstruct the previous status.
The "CBS Correction Vehicle Data" service function is available if a reset has been carried out erroneously . In
this way, the availability of a maintenance scope can be corrected to a realistic value.
A data or a mileage/kilometer reading is entered for correction. These data are converted internally into an
availability in %. In so doing, the BMW diagnosis system only accepts a smaller value as the current reading in
the control unit. In addition, the service counter of the scope is automatically reduced by one counter.
The inputs are used in the Service Booklet to determine the realistic availability. A realistic availability can be
reconstructed on a scope-specific basis by means of the last maintenance measure (with mileage/km reading and
date).
This does not include correcting the availability for brake pads. The brake pad residual thickness must be
measured and input (in millimeters).
NOTE: Reference for distance- and time-dependent maintenance scopes
For a correction, the availability is referred to the distance- and time-dependent calculation.
61 00... NOTES ON HANDLING OPTICAL FIBERS
CAUTION: To avoid damage when handling optical fibers, comply with the following
points:
 The minimum permitted bending radius is 25 mm

 Do not subject optical fibers to compressive and tensile load
 Protect optical fibers against the effects of heat > or = 85°C (e.g.
during welding work, drying work with infrared heater or hot air
blower)
 Optical fibers are permitted to show only one junction point (bridge),
replace optical fibers if necessary
NOTE: The optical fibers are colored differently as follows:
 Green=MOST (M edia O riented S ystems T ransport) optical fibers

 Yellow=ISIS (I ntelligent S afety and I ntegration S ystem) optical fibers
 Orange=repair optical fibers
Follow instructions for Processing Cables And Optical Fibers.
6100... NOTES ON HANDLING WIRING HARNESSES AND CABLES
The following applies in general:

2007 BMW 335i
To avoid damage, observe the following instructions:
 Avoid compressive and tensile loads

 Make sure cables are laid without kinks or abrasions
 Ensure non-contacting routing at sharp-edged body components; use edge protection if necessary
 Secure additionally laid cables/lines with cable straps
The following additionally applies
Shielded lines
Contact points in the shield can cause problems with regard to noise radiation and interference immunity.
Consequently, distinctions have to be drawn between the following types:
Coaxial line
 Shielded RTK031 coaxial lines may only be repaired with special crimping tools.
CVBS lines
 CVBS lines may not be repaired.

 CVBS lines must be replaced in their entirety.
HSD lines
 HSD lines may not be repaired.

 HSD lines must be replaced in their entirety.
Optical fibre cable:
NOTE: Optical fibre cables are colored differently as follows:
 Green = MOST (M edia O riented S ystems T ransport) optical fibre

 Yellow = ISIS (I ntelligent S afety I ntegration S ystem) optical fibre
 Orange = repair optical fibre cables
IMPORTANT:  Optical fibre cables are permitted to show only one separation point
(bridge), replace optical fibre cables if necessary
 Smallest permissible bending radius is 25 mm
 Avoid influence of heat = 85°
TREATING CABLES AND FIBER-OPTIC CABLES
FlexRay:
2007 BMW 335i
It is possible to repair the FlexRay. In the event of damage, the cables can be joined with conventional BUTT
CONNECTORS.
NOTE:  The line is a twisted cable. If possible, maintain twist in line after repair.
Airbag lines:
REPAIRING AIRBAG CABLES
Ribbon cables:
REPAIRING RIBBON CABLES
6113... TREATING CABLES AND FIBER-OPTIC CABLES
Notes
NOTE: Special tools referred to in the repair instructions below are contained in the
following special tool kits:
SPECIAL TOOLS REFERENCE CHART

Repair range for vehicle electrical system
Crimping set with tool for fibre-optic cables, Micro 61 4 320
Power Quadlock (MPQ), Micro Quadlock System
(MQS) contacts and universal crimping head
Insulation displacement tool for ribbon cable 61 1 190
Subject of repair instructions
 SPECIAL TOOLS FOR WIRING HARNESS REPAIRS

 CUTTING TO LENGTH AND STRIPPING INSULATION FROM CABLES
 CRIMPING STOP PARTS.
 BUTT CONNECTOR FOR REPAIRING A PLUG CONNECTION
 INSTALLING FAN CONNECTOR FOR RETROFITTING/REPAIRS
 Aerial elbow plug on radio receiver
 CUTTING OFF, STRIPPING INSULATION AND CUTTING OPTICAL FIBRES TO LENGTH
 CRIMPING OPTICAL FIBRES
 Insulation displacement connector for REPAIRING RIBBON CABLES
61 00... REPAIRING AIRBAG CABLES
IMPORTANT: Only repair those cables which show visible signs of damage. In the event of
visible damage, make sure there is only one cable repair in effect after the
repair work. If no visible damage can be identified, the entire cable must be
2007 BMW 335i
replaced.
Safety regulations:
Safety regulations for Handling Components Of Airbag System.
Instructions For Disconnecting And Connecting Battery.
Procedure for cable repair
In event of non-visible damage to wiring harness:
Disconnect plug connection on airbag module or on adapter plug. It is absolutely vital to disconnect the contacts
in succession as there is a risk of them being mixed up! Cut through one cable after the other at an appropriate
position, do not under any circumstances cut through both cables at the same time. Insulate cables remaining in
wiring harness with insulating tape. Now disconnect plug connection on airbag control unit. Unpin contacts. Cut
through one cable after the other at an appropriate position and insulate with insulating tape, do not under any
circumstances cut through both cables at the same time. Pin contacts of repair cable for airbag control unit in
control unit plug, assignment of repair cables is relevant. Lay repair cable in car parallel to existing airbag lead.
Now pin in contacts for airbag control unit or contacts of adapter plug, assignment of repair cables is relevant.
Cut off excess length of repair cable in proximity (visible area) of airbag module or of adapter plug. Twist open
cables. With the connectors and shrink-fit hoses in the Electronic Parts Catalogue (EPC), reconnect the cables
with the same cable colors. Twist cables again, open length (twist) must not exceed 40 mm. Secure interface
(shrink-fit hoses) with insulating tape to prevent cables from twisting open..
Instructions for cutting off, insulating, crimping cables, in stalling and removing contacts:
Cutting Off And Insulating Cables.
Repairing A Plug Connection Using Connectors.
Installing And Removing Contacts.
In event of visible damage:
Expose cable at damaged areas. Cut through one cable after the other at an appropriate position and insulate
cables no longer required in wiring harness with insulating tape, do not under any circumstances cut through
both cables at the same time. Now, depending on the scope of work, unpin contacts either on airbag control
unit/airbag module or on adapter plug. Cut off unpinned cables. Insulate cables remaining in wiring harness
with insulating tape. Now pin in contacts of repair cable, assignment of repair cables is relevant. Lay repair lead
in car parallel to existing airbag lead up to cutting point. Cut off excess length of repair lead. Twist open cables.
Connect cables with connectors and shrink-fit hoses in Electronic Parts Catalogue (EPC), assignment of repair
cables is relevant. Twist cables again, open length (twist) must not exceed 40 mm. Secure interface (shrink-fit
hoses) with insulating tape to prevent cables from twisting open.
Instructions for cutting off, insulating, crimping cables, in stalling and removing contacts:
2007 BMW 335i
Cutting Off And Insulating Cables.
Repairing A Plug Connection Using Connectors.
Installing And Removing Contacts.
61 00... SAFETY INSTRUCTIONS FOR HANDLING VEHICLE BATTERY
Battery acid is highly corrosive:
Do not allow any battery acid to come into contact with the eyes, the skin or clothing. Therefore wear protective
clothing, gloves and goggles.
Do not tilt the battery, acid may emerge from the vent opening.
In event of contact with acid:
If acid is splashed in to the eyes, rinse them immediately for several minutes with clear water. You must then
consult a doctor without delay.
If acid is splashed onto the skin or clothing, neutralize it immediately with a soapy solution and rinse with lots
of water.
Seek medical attention immediately if battery acid is accidentally swallowed.
Explosion hazard:
Strictly no flames, sparks, naked light or smoking!
A highly explosive mixture of electrolytic gas is created when batteries are charged. The rooms where charging
is carried out must therefore always be well ventilated.
Avoid the formation of sparks when handling cables, wiring and electrical devices.
Turn the ignition lock to the 0 position before disconnecting or connecting the battery.
Do not place tools or any similar object on the battery (danger of short-circuiting and explosion!).
1200... NOTES/INFORMATION ON START ASSISTANCE (JUMP STARTING)
Do not start the engine with help of starting sprays.
Preparation
Conform with the following when starting the engine with a jump starting cable.
 Ensure that the jump starting cable wires are of appropriate cross-section size.
2007 BMW 335i
 Only use fuse-protected jump starting cables.

 Check whether the current-supplying battery has 12 V voltage.
 If the engine is started from the battery of another vehicle, ensure that there is no contact between the
bodies of both vehicles.
IMPORTANT: Never touch electrically live ignition system components: high voltage - danger
of injury!
If the battery in the vehicle supplying power is weak, start the engine of this vehicle and let it run at idling
speed.
Operation
It is essential to conform to the procedures so as to avoid injury to persons or damage to parts.
 Automatic transmission: select drive position "P", apply parking brake.

 Manual transmission: move gear lever to neutral position, apply parking brake.
 Ensure that the jump leads cannot get caught in rotating parts, e.g. fan.
 First connect both positive poles of the batteries with one jump starting cable (red).
 Use the battery positive terminal in the engine compartment for vehicles with the battery in the luggage
compartment.
 Then use the second jump starting cable (black) to connect the negative post of the current-supplying
battery with the earth/ground point (not the negative pole or the body) of the vehicle to be started.
IMPORTANT: Do not connect the second jump starting cable (black) with the negative pole of
the battery in the vehicle to be started. Produced gas could be ignited by
sparks.
Risk of explosion!
After the engine of the vehicle to be started has fired, first disconnect the jump starting cable between the
negative pole and the earth/ground point. Then remove the starting cable from the positive poles.
61 00 VERSION WITH AFS (ACTIVE FRONT STEERING): SETTING STEERING ANGLE (AFTER
RECONNECTING VEHICLE BATTERY)
After RECONNECTING the vehicle battery, carry out the following procedure for setting the steering angle:
 Start engine.
 Turn steering wheel left to full lock.
 Turn steering wheel right to full lock.
 Turn steering wheel to central position.
 Turn off engine.
 Turn on ignition (terminal 15), AFS telltale and Check Control message go out.
2007 BMW 335i
NOTE: Entry in the fault memory remains unaffected by this procedure, therefore if
necessary:

 Clear fault memory
WIRING HARNESS
61 11... INSTALL THE REPAIR CABLE FOR THE POSITIVE BATTERY CABLE VVT
The repair instructions describe the installation of repair cables for positive battery cable VVT (BMW Parts
Department 9 303 031).
Read and comply with notes on HANDLING WIRING HARNESSES AND WIRING!
Read and comply with notes on CRIMPING STOPS!
Partially remove REAR RIGHT WHEEL ARCH COVER
Remove battery.
NOTE: Work is shown on the E91 by way of example.
There may be differences in detail in the case of other vehicle types and
equipment specifications.
NOTE: Figure shows the following lines (2):
 Left: Positive battery cable VVT (thinner cable)

 Right side: Positive battery cable (thicker cable)
Remove positive battery cable VVT left only!
Unclip the left cover (1) and loosen the nut beneath it (tightening torque 8 Nm).
Remove the positive battery cable VVT left (2).

2007 BMW 335i
Fig. 3: Identifying Cable Lug Mounting From Positive Battery Leads And Cap
Twist tension ring left (1) in direction of arrow and remove.
Installation note:
Ensure that the tension rings (1) are correctly seated.
Fig. 4: Removing Clamping Rings

Release screws (1).
Slightly lower the cover (2) at the point marked with an arrow.
2007 BMW 335i

Release screws (1) and cable straps (2) from positive battery cable VVT (3). Lower the cable channel (4) and
remove the positive battery cable VVT (3) from the cable channel (4).
Fig. 6: Identifying Positive Battery Cable VVT, Screws, Cable Straps, And Cable Channel
A. Measure and mark the length (1) = 23 cm on the positive battery cable VVT (2).
B. Disconnect the positive battery cable VVT (2) at the marked point with special tool 2 337 974 (cable
shears).
C. At the end of the positive battery cable VVT (2), measure and mark 1 cm.
D. Strip the insulation off the positive battery cable VVT (2) at the marked point with special tool 2 337 974
(cable shears).
IMPORTANT: Do not damage the strands during stripping!

2007 BMW 335i
Fig. 7: Identifying Measuring, Cutting, And Stripping Points

Attach the heat-shrink tubing (2) on the repair positive battery cable VVT (3).
Position the repair positive battery cable VVT (3) as shown with the arrow.
Crimp the positive battery cable VVT on the vehicle (1) and repair positive battery cable VTT (3) with special
tool 61 0 202 .
2007 BMW 335i
Fig. 8: Attaching Heat-Shrink Tubing And Crimping Positive Battery Cable VVT On Vehicle And
Repair Positive Battery Cable VTT
A. Centrally measure and mark distance (1) = 7.5 cm as shown.

B. Position the heat-shrink tubing (2) over the crimping location so that mark (3) is must barely visible.
C. Shrink the heat-shrink tubing (2) with hot air blower 0 444 131. Use soldering shrink reflector (5)! (Heat
shrink temperature 400 °C)
D. After shrinking, adhesive (4) must emerge from both sides of the heat-shrink tubing (2).
NOTE: If the body has corrosion damage in the area of the transfer support point, it
must be repaired prior to installing the repair positive battery cable VVT
according to the BMW guidelines.
Following the completed repair, the body and positive battery connection point
must be sprayed with cavity preservation in a diameter of 20 cm.
Fig. 9: Identifying Application Of Head Shrink Tubing

AUXILIARY CABLE
2007 BMW 335i
61 12 002 REPLACING BATTERY POSITIVE LEAD (FROM BATTERY TO LUGGAGE

COMPARTMENT CONNECTOR)
WARNING: Observe Safety Instructions for handling vehicle battery.
Notes and instructions on Intelligent Battery Sensor IBS.
IMPORTANT: Do not under any circumstances pull/lever safety battery terminal off by force.
Crash protector must be reinstalled!
 Remove Flap In Luggage Compartment Panel on right

 Remove Distribution Box
 Remove Battery
Disconnect plug connection (1) on safety battery terminal (2).
Fig. 10: Identifying Plug Connection And Safety Battery Terminal

For tightening torque refer to 61 12 1AZ in 61 12 AUXILIARY CABLES/LEADS .
Remove cable lug mounting from positive battery lead (2).
WARNING: Risk of short circuits!
When installing, ensure:

2007 BMW 335i
 Correct screw connection

 Correct seating of cable lug mounting on positive battery lead (2)
 For tightening torque refer to 61 12 1AZ in 61 12 AUXILIARY
CABLES/LEADS .
Fig. 11: Identifying Positive Battery Lead And Cap

61 12 004 REPLACING BATTERY POSITIVE LEAD (FROM LUGGAGE COMPARTMENT

CONNECTOR TO ENGINE BULKHEAD CONNECTOR)
 Remove Battery battery

 E93 only:
Remove vibration damper
Remove cable lug mounting from positive battery leads (2).

2007 BMW 335i
Fig. 12: Identifying Positive Battery Leads And Cap

Turn clamping rings (1) in direction of arrow and remove.
Installation:
Make sure clamping rings (1) are correctly seated.
Fig. 13: Identifying Clamping Rings And Removal Direction

Remove Right Underbody Panelling.
Remove Fuel Tank.
Pull battery positive lead (1) out of luggage compartment floor (2).
2007 BMW 335i
Fig. 14: Identifying Battery Positive Lead And Luggage Compartment Floor
Release screw (1).
Remove cover (2) and release cable holder.
Fig. 15: Identifying Screw And Cover

Release cable holder (1).

2007 BMW 335i
Fig. 16: Identifying Cable Holder

Remove Electronics Box.
Remove protective cap (1).
Release nuts underneath.
Remove positive battery cable.
Fig. 17: Identifying Protective Cap

Remove front right Wheel Arch Cover (Rear Section).
Release cable strap (1).
Remove battery positive lead in downward direction.

2007 BMW 335i
Fig. 18: Identifying Cable Strap And Removal Direction

61 12 013 REPLACING BATTERY NEGATIVE LEAD

 Remove Top Trim From Tail Panel
Slacken nut (2) on battery negative terminal.
For tightening torque refer to 61 21 1AZ in 61 21 BATTERY WITH TERMINAL .
IMPORTANT: Do not under any circumstances use force to pull off pole shoe.
Do not under any circumstances release socket-head cap screw of IBS.
Detach battery negative lead (3) with intelligent battery sensor (IBS) in upward direction.
Release nut (4) and remove cable.

2007 BMW 335i
Fig. 19: Identifying Plug Connection, Battery Negative Lead And Nut
Vehicles up to 12/2006 with IBS:
NOTE: IBS2004 is replaced by IBS2006.
 Remove battery crash element without replacing
Fig. 20: Identifying Battery

61 12 200 REPLACING WIRING HARNESS IN LEFT OR RIGHT FRONT DOOR
 Close front side window completely

 Remove Front Acoustic Insulation
 Remove Trim On Mirror
2007 BMW 335i
Disconnect plug connection (1) for outside door handle light.
Disconnect plug connection (2) on outside door handle for
Comfort Access.
Disconnect plug connection (3) on power window unit.
Disconnect plug connection (4) for door mirror.
Unclip door wiring harness at points (5).
Fig. 21: Identifying Plug Connections And Wiring Harness Clipping Point
Installation:
Make sure door wiring harness is correctly laid.
Release screw (1), fold door wiring harness plug on A-pillar (2) downwards slightly and remove.
Disconnect plug connection behind.
Pull rubber grommet (3) out of front door.
Feed out door wiring harness towards front to A-pillar.

2007 BMW 335i
Fig. 22: Identifying A-Pillar, Rubber Grommet And Screw

PLUG CONNECTION, TERMINALS, FUSE BOX

61 13 BUTT CONNECTOR FOR REPAIRING A PLUG CONNECTION
 61 0 300
 61 9 040
IMPORTANT: 1. Identify cause of damage (e.g. sharp-edged body parts, faulty electrical
loads, jammed mechanisms, corrosion caused by ingress of water, etc.).
2. Read out fault memory
3. Eliminate cause of damage.
4. Disconnect battery negative terminal
5. Make sure that no safety-related system according to connection scheme
(e.g. anti-lock braking system, active rear-axle kinematics, airbags, etc.)
are influenced. Otherwise replace faulty wiring harness or use repair
cable.
6. Carry out function test and read out fault memories again
7. Eliminate new faults if applicable and clear fault memories
NOTE: The repair range IV for vehicle electrical system contained the required special
tools and individual parts for retrofitting and repair work with the aid of fan
connectors.
The case can no longer be ordered.
Special tools:
2007 BMW 335i
 Special tool 61 9 040
Choose repair kit.
Example: Repair kit, circular plug system D 2.5.
Fig. 23: Identifying Repair Kit

Fig. 24: Identifying Circular Plug System

Remove following parts:
1. Prepackaged end of cable with requisite wire cross-section

2. Crimp connector for selected wire cross-section
3. Shrink-fit hose
2007 BMW 335i
Fig. 25: Identifying Prepackaged End Of Cable, Crimp Connector And Shrink-Fit Hose
Open secondary lock on housing.
Mark damaged contact (4) with socket number of housing and press it out of housing using relevant special tool
contained in special tool kit 61 0 300.
Refer to repair instructions:
Opening Plug Housings And Removing Contacts of different plug systems
Fig. 26: Identifying Damaged Contact

IMPORTANT:  Check maximum length of repair cable!

 If more than one wire is to be repaired, the individual interfaces must be
offset so that the wiring harness is not too thick at the repaired point.
2007 BMW 335i
Fig. 27: Identifying Special Tool

Observe following procedure:
 Cut off wire with faulty contact at point which is easily accessible.
 Strip wiring-harness wire end (6).
 Cut pre-assembled wire end (7) to length and strip insulation.
Refer also to repair instruction:
Cutting To Length And Stripping Insulation From Cables
Crimp butt connector on pre-assembled wire end.
Crimping On Stop Parts
Fig. 28: Identifying Crimp Butt Connector On Pre-assembled Wire End

Push shrink-fit hose (8) onto free wire end.

2007 BMW 335i
Fig. 29: Pushing Shrink-Fit Hose Onto Free Wire End

Crimp unused wire end to butt connector.
Fig. 30: Crimping Wire End To Butt Connector

Pull shrink-on sleeve over butt connector.
Fig. 31: Pulling Shrink-On Sleeve Over Butt Connector

2007 BMW 335i
IMPORTANT: Do not burn shrink-on sleeve.
With hot air blower, shrink the shrink-on sleeve on both sides (9) of shrink-fit hose until glue emerges
uniformly all round.
Insert contact in housing.
Close secondary lock on housing.
Fig. 32: Identifying Shrink-On Sleeve On Both Sides Of Shrink-Fit Hose

6113... CONNECTOR HOUSING, LCC CONTACT (LOAD CURRENT CONTACT)
Notes
Socket housing:
Press lock (1) with suitable tool (2) in direction of arrow out of socket housing (3).
Fig. 33: Pressing Lock Using Tool

2007 BMW 335i
Pull lock (1) out of socket housing (2).
Fig. 34: Pulling Lock Out Of Socket Housing

Insert special tool 61 0 317 into socket housing (1) and pull out lead with LCC contact (2) in direction of arrow.
Fig. 35: Pulling Out Lead With LCC Contact

Pin housing:
Unlock locking slide (1) of pin housing (2) with suitable tool (3) in direction of arrow.
2007 BMW 335i
Fig. 36: Unlocking Locking Slide Of Pin Housing Using Tool

Insert special tool 61 0 317 into pin housing (1) and pull out lead with LCC contact (2) in direction of arrow.
Fig. 37: Pulling Out Lead With LCC Contact

6113... CRIMPING MICRO POWER QUADLOCK CONTACTS (MPQ)
Notes
To crimp MPQ contacts, use pliers 61 4 321 (1) in conjunction with crimping head 61 4 325 (2) from crimping
set 61 4 320 .
NOTE: Pliers (1) open automatically as far as they will go when handles are pressed
together.
2007 BMW 335i
Fig. 38: Identifying Hand Pliers With Crimping Head (61 4 325)
Open pliers (1).
NOTE: Place contact (2) with utmost care in designated nest (observe cable cross-
section) in crimping head (3). Make sure it is exactly positioned.
Place MPQ contact (2) in crimping head (3).
Close pliers (1) one notch.
Fig. 39: Identifying Hand Pliers With Crimping Head And MPQ Contact
NOTE: Follow procedure for CUTTING AND STRIPPING INSULATION from cables.
Insert stripped cable (2).

2007 BMW 335i
Close pliers (1) fully.
Open pliers (1) and remove cable (2).
NOTE: Check contact for CORRECT CRIMPING.
Fig. 40: Removing Cable Using Hand Plier

6113... CRIMPING MICRO QUADLOCK SYSTEM CONTACTS (MQS)
Notes
To crimp MPQ contacts, use pliers 61 4 321 (1) in conjunction with crimping head 61 4 324 (2) from crimping
set 61 4 320 .
together.
2007 BMW 335i
Open pliers (1).
Fold up contact carrier (2).
Insert MQS contact (3) in contact carrier (2).
Fold back contact carrier (2).
Fig. 42: Inserting MQS Contact In Contact Carrier Of Plier

NOTE: Follow procedure for CUTTING AND STRIPPING INSULATION from cables.
Close pliers (1) one notch.
Insert stripped cable (2).

2007 BMW 335i
Fig. 43: Inserting Stripped Cable

Open pliers (1).
Open contact carrier (2) gently and carefully remove MQS contact.
NOTE: Check contact for CORRECT CRIMPING.
Fig. 44: Removing MQS Contact

6113... CRIMPING ANNULAR CONTACTS
Crimping annular contacts
Special tool 61 4 320
6113... CRIMPING OPTICAL FIBRES

2007 BMW 335i
Notes
To crimp optical fibres, use pliers 61 4 321 (1) in conjunction with crimping head 61 4 323 (2) from crimping
set 61 4 320 .
together.
Move contact guide by means of stop lever (1) into corresponding position (pin contact or jack).
Fig. 46: Identifying Stop Lever On Plier

Open pliers (2).
Place pin contact or jack (1) in crimping head and secure with locking lever (3).
2007 BMW 335i
Fig. 47: Placing Pin Contact Or Jack On Crimping Head

NOTE: Follow procedure for CUTTING AND STRIPPING INSULATION.
Insert stripped optical fibre (1) as far as it will go into pin contact or jack (2).
Open pliers (3) and locking lever (4).
Remove optical fibre (1).
Fig. 48: Removing Optical Fibre

IMPORTANT: Make sure optical fibre is correctly seated in jack.

Right (A)
End of optical fibre (1) must be flush with tip of pin contact (2).
2007 BMW 335i
Wrong (B)
End of optical fibre (1) is not flush with tip of pin contact (2).
Fig. 49: Identifying Optical Fibre End With Pin Contact Tip
61 13 CRIMPING STOP PARTS
 12 1 080
 12 1 081
 12 1 083
1. Crimping contact sleeves for fan connectors 4 mm2 and ignition cable contacts
Special tool kit 12 1 080 is used to fit ignition cable contacts and to crimp 4 mm2 contact sleeves for fan
connectors.
 12 1 081 (hand crimping tool)

 12 1 083 (matrix)
Special tools for wiring harness repairs

2007 BMW 335i
Fig. 50: Identifying Special Tool (12 1 081) And (12 1 083)
Unlock special tool 12 1 081:
Squeeze grips (1) lightly and push unlocking lever (2) in direction of arrow.
Or:
Compress handles as far as they will go, tool unlocks automatically.
Fig. 51: Identifying Grips And Unlocking Lever

Insert contact sleeve 4 mm2 in nest with lock (1) as far as it will go.
2007 BMW 335i
Fig. 52: Inserting Contact Sleeve In Nest With Lock

Preload contact by squeezing matrix in crimping tool. Grip contact (1) firmly only, do not crimp.
Fig. 53: Identifying Crimping Tool Grip Contact

NOTE: Follow procedure for Cutting And Stripping Insulation from cables.
Insert stripped end of wire (7) in the contact. Ensure insulation and stripped wire end are correctly laid in
contact.
Compress crimping tool as far as it will go.
Crimping tool unlocks automatically.
Take contact out of crimping tool.

2007 BMW 335i
Fig. 54: Inserting Stripped End Of Wire In Contact

2. Checking crimping
Check insulation crimp (8) and wire crimp (9) against following illustrations to ensure crimps are
correctly located.
NOTE: Illustration shows butt connectors and contact sleeves for fan connectors
knocked on one side. The crimping procedure is identical here.
Fig. 55: Identifying Insulation Crimp And Wire Crimp

Correct crimping:
Visible conductor end (10).
Visible insulation end (11).

2007 BMW 335i
Fig. 56: Identifying Insulation End And Conductor End

Incorrect crimping:
Conductor end (10) inserted too far.
Insulation end (11) in wire crimp.
If necessary, repeat crimping with a new contact.
Fig. 57: Precaution For Insulation End And Conductor End

Incorrect crimping:
Conductor end (10) not visible.
Insulation end (11) not visible.
If necessary, repeat crimping with a new contact.

2007 BMW 335i
Fig. 58: Precaution For Insulation End And Conductor End

61 13 CUTTING TO LENGTH AND STRIPPING INSULATION FROM CABLES
Stripped length:
STRIPPED LENGTH CHART

Wire cross-section (mm2 ) Stripped length (mm)
0.35... 0.50 4.0
0.75... 1.00 4.5
1.00... 2.50 5.0
61 13... DME MASTER RELAY CONNECTOR
Unlock locking flap (1) of corresponding cable.
Fig. 59: Identifying Locking Flap And Removal Direction

With special tool 61 1 136 or 61 1 137 (ejector), press back arrester hook (2) of appropriate contact and pull out
cable.
2007 BMW 335i
Fig. 60: Inserting Arrester Hook

61 13 OPENING PLUG HOUSINGS AND REMOVING CONTACTS OF DIFFERENT PLUG

SYSTEMS
 61 0 300
 61 0 400
 61 1 150
Abbreviations and what they mean:
ABBREVIATIONS CHART
D 1.5 / 2.5 Round contacts of 1.5 mm or 2.5 mm diameter
MDK 3plus Miniature double flat spring contact
JPT ELA Junior Power Timer flat spring contacts with strand sealing
DFK ELA Double flat spring contacts with strand sealing
Electronic contacts with and without strand sealing
Elo
Manufacturer: Siemens
Electronic contacts for heavy loads with and without strand sealing
Elo Power
Manufacturer: Siemens
Micro Quadlock System electronic contacts with and without strand sealing
MQS
Manufacturer: AMP
Micro Power Quadlock electronic contacts for heavy loads with and without strand sealing
MPQ
Manufacturer: AMP
Ultrasonic-welded connectors:
Ultrasonic-welded connectors (1) can be identified by the welds (2) on their longitudinal side.
The contacts of these connectors cannot be replaced.

2007 BMW 335i
Replace plug completely.
Fig. 61: Identifying Ultrasonic-Welded Connectors And Side Welds

Release and press-out tool 61 1 150
Replaced as from 09/2005 by: 61 0 300
61 0 400
Repair instructions for opening plug housings and removing contacts of different plug systems
Plug system D 1.5/D 2.5:
 Circular plugs, 7-, 8-pin, System D 2.5

 Circular plugs, 13-pin, System D 2.5
 Circular plugs, 20-pin, System D 2.5
 Circular plugs, 4-, 7-, 10-, 12-, 25-pin, System D 1.5/D 2.5
 In-line plugs, 15-pin, System D 2.5
 In-line plugs, 8-, 12-pin, System D 2.5
Plug system JPT/MDK/DFK:
 In-line plugs, 2-pin, System JPT ELA

 In-line plugs, 2-pin, System MDK 3plus 2.8
 In-line plugs, 4-pin, System DFK ELA
2007 BMW 335i
Plug system Elo/Elo-Power:
 In-line plugs, 4-, 10-pin, System Elo

 In-line plugs, 6- to 50-pin, System Elo
 In-line plugs, 3-, 6-pin, System Elo-Power 2.8
Plug system MQS/MPQ:
 In-line plugs, 6-, 8-pin, System MQS

 In-line plugs, 2-pin, System MPQ 2.8
 Control unit plugs, 25-, 35-, 55-, 83-, 88-pin
 In-line plugs, 24-pin, Hybrid System MQS/MPQ
 Socket housing 42-, 43-pin, Hybrid System MQS / MPQ
 Socket housings 2x21-, 2x27-pin, Hybrid System MQS/MPQ, Elo/Elo-Power
 In-line plugs, 30-pin, Hybrid System MQS/MPQ
 Socket housings, 5-, 8-pin, System MQS/MPQ
 Socket Housing (Radio Plug), Hybrid System MQS/MPQ
61 13.. REMOVING AND INSTALLING/REPLACING FIBRE-OPTIC CABLE CONNECTOR
IMPORTANT: Comply with notes and instructions on Handling Fibre-Optic Cables.
 Remove Side Section On Rear Seat Backrest on left
Unlock catch (1) and remove deflection roller (2).
Remove fibre optic cable (3) from deflection roller (2).
Unlock fibre optic cable plug (4) and remove.

2007 BMW 335i
Fig. 62: Identifying Catch, Fibre Optic Cable, Deflection Roller And Fibre Optic Cable Plug
Carefully raise cover cap (1) and remove from fibre optic cable plug (2).
Fig. 63: Identifying Cover Cap And Fibre Optic Cable Plug
Carefully raise lock (1) and pull fibre optic cable (2) out of fibre optic cable plug (3).
Installation:
Make sure fibre-optic cable (2) is correctly seated in fibre-optic cable connector (3).
Fig. 64: Identifying Lock, Fibre Optic Cable And Fibre Optic Cable Plug
61 13.. UNLOCKING AND DISCONNECTING DIFFERENT PLUG CONNECTIONS
NOTE: Examples of unlocking and disconnecting different plug connections.
Press lock and open clip in direction of arrow.

2007 BMW 335i
Fig. 65: Pressing Lock And Disconnecting Plug Connection

Press lock and open clip in direction of arrow.

Open clip in direction of arrow and disconnect plug connection in direction of arrow.
2007 BMW 335i
Fig. 67: Opening Clip And Disconnecting Plug Connection

Press lock and disconnect plug connection in direction of arrow.


2007 BMW 335i




2007 BMW 335i


61 13... BASE OF TAB CONNECTOR HOUSINGS
Unlock hook (1) with special tool 61 1 360 and slide plug housing downwards out of base.
2007 BMW 335i
Fig. 74: Identifying Special Tool (61 1 360) And Hook

61 13... CUTTING OFF, STRIPPING INSULATION AND CUTTING OPTICAL FIBRES TO LENGTH
 61 4 320
To cut off, strip insulation and cut optical fibres to length, use pliers 61 4 321 (1) in conjunction with crimping
head 61 4 322 (2) from crimping set 61 4 320.
together.
Fig. 75: Identifying Pliers (61 4 321) And Crimping Head (61 4 322)
Cutting optical fibre
Open pliers (1).

2007 BMW 335i
Place optical fibre (2) in cutting device (3).
Close pliers (1) and remove optical fibre (2).
Fig. 76: Identifying Pliers, Cutting Device And Optical Fibre

Stripping insulation from optical fibre
Open pliers (1).
Open lever (2) in direction of arrow.
Fig. 77: Identifying Pliers And Lever

Slide optical fibre (1) into stripping device (2) until flush at point (3).
Close clamping lever (5) in direction of arrow.
Open pliers (4) by one tooth notch.

2007 BMW 335i
Open clamping lever (5) against direction of arrow again and remove optical fibre (1).
Fig. 78: Identifying Stripping Device, Point, Clamping Lever, Pliers And Optical Fibre
NOTE: A stripping replacement blade set is available under number 61 4 327.
Cutting optical fibre to length
IMPORTANT: The cutting blade must be replaced prior to each cutting of the optical fibre.
Pull pin (1) in direction of arrow.
Fold up blade retaining link (2) in direction of arrow.
Fig. 79: Identifying Pin And Blade Retaining Link

WARNING: Risk of injury when changing the blade.

2007 BMW 335i
Remove blade (1) and replace.
Installation:
Make sure blade (1) is correctly seated on locating points (2).
Fig. 80: Identifying Blade And Locating Points

Open pliers (3).
Slide optical fibre (1) into cutting device (2) until insulation of optical fibre (1) butts against clamping device.
Close pliers (3) fully and keep closed.
Remove optical fibre (1).
Fig. 81: Identifying Cutting Device, Optical Fibre And Pliers

6113... FUSE HOLDER
Remove appropriate fuse from fuse holder (1).

2007 BMW 335i
NOTE: Identify the position when removing fuses.
Pull sliding lock (2) out of fuse holder (1) completely.
Fig. 82: Identifying Sliding Lock On Fuse Holder

With special tool 61 0 316 or 61 0 313 (pressing-off tool) from kit 61 0 300 , press back retaining hooks (3) of
appropriate contact and pull out cable.
Fig. 83: Pressing Back Retaining Hooks Using Special Tool

61 13... IN-LINE PLUGS, 2-PIN, SYSTEM JPT ELA
Press lock (1) in direction of arrow and slide connector forward.

2007 BMW 335i
Fig. 84: Locating Lock

Press lock (1) downward and slide out to one side.
Fig. 85: Locating Lock

With special tool 61 0 316 from kit 61 0 300 , unlock contact and pull out cable (1) with contact towards rear.
2007 BMW 335i
Fig. 86: Removing Cable Using Special Tool 61 1 132

6113... IN-LINE PLUGS, 24-PIN, HYBRID SYSTEM MQS/MPQ
Manufactured by AMP: The following contact types without strand sealing can be fitted in the plug housings:
 MQS (Micro Quadlock System)

 MPQ, width 2.8 mm (Micro Power Quadlock)
Socket housing
Press locks (1) on cap (2) upwards on both sides.
Detach cap from contact carrier (3).
NOTE: Detaching the cap releases the secondary locks of the socket contacts.
Fig. 87: Pressing Locks On Cap

2007 BMW 335i
Hold down retaining hook (1) of socket contact in opening of contact carrier with a small screwdriver.
Pull wire with socket contact in direction of arrow as far as secondary lock (2).
Fig. 88: Pulling Wire With Socket Contact

Hold down retaining hook in secondary lock (1) again and pull cable with socket contact (2) completely out of
contact carrier (3).
Fig. 89: Pulling Cable With Socket Contact Out Of Contact Carrier
Pin housing
Press locks (1) on cap (2) upwards on both sides.
Detach cap from housing carrier (3).
NOTE: Detaching the cap releases the secondary locks of the pin contacts in the
2007 BMW 335i
contact carriers.
Fig. 90: Detaching Cap From Housing Carrier

Pull contact carrier (1) out of housing carrier (2).
The pin contacts are pulled out of a contact carrier as described under "Socket housing".
Fig. 91: Pulling Contact Carrier Out Of Housing Carrier

61 13... IN-LINE PLUGS, 30-PIN, HYBRID SYSTEM MQS/MPQ

Socket housing:
2007 BMW 335i
Raise lock (1) on housing (2).
Push contact carrier (3) from rear out of housing (2).
NOTE: Pushing out the contact carrier releases the secondary locks of the socket
contacts.
Fig. 92: Identifying Lock, Contact Carrier, Housing And Removal Direction
Fig. 93: Identifying Retaining Hook, Secondary Lock And Removal Direction
2007 BMW 335i
Fig. 94: Identifying Secondary Lock, Socket Contact, Contact Carrier And Removal Direction
Pin housing:
Contacts 1... 13 and 19... 27:
Raise locking slide (1) on both sides (2) of housing and detach.
NOTE: Detaching the locking slide releases the secondary locks of the pin contacts.
Fig. 95: Identifying Locking Slide, Sides And Removal Direction

Contacts 14... 18 and 28... 30:
Pull slide (1) outwards completely.
Raise lock (2) on housing.
Pull contact carrier (3) out of housing.

2007 BMW 335i
NOTE: Pulling out the contact carrier releases the secondary locks of the pin contacts.
Fig. 96: Identifying Lock, Contact Carrier, Slide And Removal Direction
The pin contacts are pulled out of a contact carrier as described under "Socket housing".
6113... IN-LINE PLUGS, 6- TO 50-PIN, SYSTEM ELO
Unlock lock.
Fig. 97: Unlocking Lock

Unfasten cable strap.
Installation:
Cable clip must be reinstalled.

2007 BMW 335i
Fig. 98: Locating Cable Strap

Detach catch (1) from plug housing (2).
Fig. 99: Detaching Catch From Plug Housing

Press out contact carrier (3) with wiring harness (4) through opening (5).
Fig. 100: Pressing Out Contact Carrier With Wiring Harness

2007 BMW 335i
Hold down arrester hook (6) of defective contact and pull cable and contact up to secondary lock (8).
Fig. 101: Pulling Cable

Hold down arrester hook once again in secondary lock (8) and pull cable and contact completely out of contact
carrier.
Fig. 102: Pulling Cable And Contact Out Of Contact Carrier

6113... INLINE PLUGS, 6-, 8-PIN, SYSTEM MQS
Press lock (1) in direction of arrow and slide plug forward.

2007 BMW 335i
Fig. 103: Pressing Lock

Press locking hook (2) downward and slide lock (1) out.
Fig. 104: Pressing Locking Hook

Press down arrester hook (1) with screwdriver and pull out cable with contact towards rear.
Fig. 105: Pulling Out Cable With Contact

61 13... INLINE PLUGS, 8-, 12-PIN, SYSTEM D2.5

2007 BMW 335i
Move upper section of connector (1) and lower section of connector (2) against each other in direction of arrow.
Fig. 106: Identifying Upper And Lower Connector Sections

With special tool 61 0 313 from kit 61 0 300 , press back retaining hook (3) of corresponding contact and pull
out cable with contact.
Fig. 107: Identifying Arrester Hook And Special Tool 61 1 132

61 13 INSTALLING COMB CONNECTOR FOR RETROFITTING/REPAIRS
 61 9 040
 61 9 041
 61 9 042
NOTE: The repair range IV for vehicle electrical system contained the required special
2007 BMW 335i
tools and individual parts for retrofitting and repair work with the aid of fan
connectors.
The case can no longer be ordered.
Special tools:
 special tool 61 9 040
Fig. 108: Identifying Repair Kit

Choose contact sleeve (up to 4 mm2 ) in accordance with wire cross-section.
Fig. 109: Identifying Contact Sleeve

Alternatively:
Choose contact sleeves (up to 2.5 mm2 ) for fan connectors.

2007 BMW 335i
Fig. 110: Identifying Contact Sleeves For Fan Connectors

Cut through wire loop in wiring harness at established point.
Strip insulation from both wire ends.
Cutting To Length And Stripping Insulation From Cables

Crimp contact sleeves on both wire ends.
Crimping On Stop Parts

2007 BMW 335i
Fig. 112: Crimping Contact Sleeves On Wire Ends

NOTE: If using repair kit for contact sleeves, refer to repair instruction Butt Connector
For Repairing A Plug Connection.
Crimp connecting cable for retrofitting likewise with contact sleeve.
Fig. 113: Crimping Connecting Cable For Retrofitting

Cut required number of poles to length for fan connectors.

2007 BMW 335i
Fig. 114: Identifying Poles for Fan Connector

Special tool 61 9 041 (hand crimping tool) in conjunction with 61 9 042 (matrix) are used for pushing contact
sleeves onto fan connectors.
Special Tools For Wiring Harness Repairs
Fig. 115: Identifying Special Tools

Unlock special tool 61 9 041:
Squeeze grips (1) lightly and push unlocking lever (2) in direction of arrow.
Or:
Compress handles as far as they will go, tool unlocks automatically.

2007 BMW 335i
Fig. 116: Identifying Unlocking Lever And Grips

Insert prepared fan connector (3) in special tool 61 9 041 / 61 9 042.
Fig. 117: Inserting Prepared Fan Connector In Special Tool

Attach wire with contact sleeve to fan connector.
Fig. 118: Attaching Wire With Contact Sleeve To Fan Connector

2007 BMW 335i
Press crimping tool together and slide contact sleeve firmly home.
Fig. 119: Pressing Crimping Tool

IMPORTANT: Once contact sleeves have been pushed on, they should not be detached again
from the fan connector or reused.
Push on further contact sleeves for potential branching.
Fig. 120: Pushing On Contact Sleeves To Prevent Potential Branching

Installation in wet area (engine compartment, wheel arch):
Apply sealing compound on both sides and press into contacts (1).
Fit shrink-fit hose and heat up with hot air blower (2) (approx. 250°C).
2007 BMW 335i
Fig. 121: Fitting Shrink-Fit Hose And Heat Up With Hot Air Blower
NOTE: Ensure that fan connector has sufficient contact surface on mounting point.
Do not heat shrink-fit hose on edges of fan connector too strongly, risk of
cracking.
Allow shrink-fit hose to cool down until hand-warm. Then press sealing material again into contacts and onto
edges of fan connector.
If necessary, carefully heat shrink-fit hose again.
Installation in dry area (interior, luggage compartment):
Slide assembled fan connector into insulation housing until it locks into place.
Fig. 122: Sliding Assembled Fan Connector Into Insulation Housing

6113... MAIN RELAY CONNECTOR FOR DME
Open locking clip (1) for the corresponding cable.

2007 BMW 335i
Fig. 123: Opening Locking Clip

With special tool 61 0 316 or 61 0 313 (pressing-off tool) from kit 61 0 300 , press back retaining hooks (2) of
appropriate contact and pull out cable with contact.
Fig. 124: Pressing Back Retaining Hooks Using Special Tool

61 13... RELAY CARRIER
Place special tool 61 1 153 on relay carrier (1) and carefully pull in direction of arrow until retaining lugs (2) on
relay carrier are raised.
2007 BMW 335i
Fig. 125: Identifying Relay Carrier And Retaining Lugs

Pull relay carrier (2) in direction of arrow into first catch (3).
Fig. 126: Identifying Relay Carrier And First Catch

Press down arrester hook (4) of appropriate contact and pull out cable with contact.
Press out double flat spring contact with special tool 61 1 136 or 61 1 137 (ejector).
2007 BMW 335i
Fig. 127: Identifying Arrester Hook

61 13 050 REMOVING AND INSTALLING OR REPLACING FUSE BOX IN PASSENGER

COMPARTMENT (BUILT AFTER 03/2007)
IMPORTANT: Read and comply with notes on HANDLING WIRING HARNESSES AND
CABLES.
 Remove right GLOVE BOX WITH HOUSING

 Remove JUNCTION BOX.
Release wiring harness fastener (2) from fuse box interior (6).
Release screws (3).

Carefully fold fuse box interior (6) forwards, feeding battery positive lead (4) in
direction of arrow out of fuse box interior holder (5).
2007 BMW 335i
Fig. 128: Feeding Battery Positive Lead Out Of Fuse Box Interior Holder
Disconnect all plug connections (1) on reverse side of fuse box interior (3).
Remove fuse box interior (3).
Installation:
Battery positive lead (2) must not be damaged.
Make sure wiring harnesses are correctly laid and plug connections (1) are correctly engaged.
Fig. 129: Identifying Plug Connections And Fuse Box Interior

Replacement:
If necessary, remove fuses and relays.
61 13... REMOVING AND INSTALLING/REPLACING OBD-II SOCKET

2007 BMW 335i
 61 0 315
 Remove Footwell Side Trim Panel On A-Pillar, Left
Release screws (1).
Remove OBD-II socket (2) from holder (3).
Fig. 130: Identifying Screws, OBD-II Socket And Holder

Remove OBD-II socket cover (2) from OBD-II socket (1).
Unlock slide plate (3) with a suitable tool in direction of arrow.
Insert special tool 61 0 315 in OBD-II socket (1) in direction of arrow and press out associated flat spring
contact (4). Press remaining flat spring contacts with special tool 61 0 315 out of OBD-II socket (1).
Installation:
Pay attention to pin assignment of OBD-II socket (1).
Make sure flat spring contacts and slide plate (3) are correctly engaged and seated in OBD-II socket (1).
2007 BMW 335i
Fig. 131: Identifying OBD-II Socket, Cover, Slide Plate, Spring Contact, Special Tool (61 0 315) And
Removal Direction
6131134 REMOVING AND INSTALLING/REPLACING USB/AUDIO INTERFACE CONNECTING

SOCKET
REMOVING AND INSTALLING/REPLACING AV CONNECTION SOCKET
6100... REPAIRING AIRBAG CABLES
IMPORTANT: Only repair those cables which show visible signs of damage. In the event of
visible damage, make sure there is only one cable repair in effect after the
repair work. If no visible damage can be identified, the entire cable must be
replaced. When carrying out repairs to the airbag wiring harness, you must use
the spare parts offered in the Electronic Parts Catalogue (EPC).
Safety regulations
See SAFETY REGULATIONS .
See INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY .
Procedure for cable repair
In event of non-visible damage to wiring harness
Disconnect plug connection on airbag module or on adapter plug. It is absolutely vital to disconnect the contacts
in succession as there is a risk of them being mixed up! Cut through one cable after the other at an appropriate
position, do not under any circumstances cut through both cables at the same time. Insulate cables remaining in
wiring harness with insulating tape. Now disconnect plug connection on airbag control unit. Unpin contacts. Cut
through one cable after the other at an appropriate position and insulate with insulating tape, do not under any
2007 BMW 335i
circumstances cut through both cables at the same time. Pin contacts of repair cable for airbag control unit in
control unit plug, assignment of repair cables is relevant. Lay repair cable in car parallel to existing airbag lead.
Now pin in contacts for airbag control unit or contacts of adapter plug, assignment of repair cables is relevant.
Cut off excess length of repair cable in proximity (visible area) of airbag module or of adapter plug. Twist open
cables. With the connectors and shrink-fit hoses in the Electronic Parts Catalogue (EPC), reconnect the cables
with the same cable colors. Twist cables again, open length (twist) must not exceed 40 mm. Secure interface
(shrink-fit hoses) with insulating tape to prevent cables from twisting open.
Instructions for cutting off, insulating, crimping cables, installing and removing contacts:
CUTTING TO LENGTH AND STRIPPING INSULATION FROM CABLES.
BUTT CONNECTOR FOR REPAIRING A PLUG CONNECTION.
OPENING PLUG HOUSINGS AND REMOVING CONTACTS OF DIFFERENT PLUG SYSTEMS.
In event of visible damage
Expose cable at damaged areas. Cut through one cable after the other at an appropriate position and insulate
cables no longer required in wiring harness with insulating tape, do not under any circumstances cut through
both cables at the same time. Now, depending on the scope of work, unpin contacts either on airbag control
unit/airbag module or on adapter plug. Cut off unpinned cables. Insulate cables remaining in wiring harness
with insulating tape. Now pin in contacts of repair cable, assignment of repair cables is relevant. Lay repair lead
in car parallel to existing airbag lead up to cutting point. Cut off excess length of repair lead. Twist open cables.
Connect cables with connectors and shrink-fit hoses in Electronic Parts Catalogue (EPC), assignment of repair
cables is relevant. Twist cables again, open length (twist) must not exceed 40 mm. Secure interface (shrink-fit
hoses) with insulating tape to prevent cables from twisting open.
Instructions for cutting off, insulating, crimping cables, installing and removing contacts:
CUTTING TO LENGTH AND STRIPPING INSULATION FROM CABLES.
BUTT CONNECTOR FOR REPAIRING A PLUG CONNECTION.
OPENING PLUG HOUSINGS AND REMOVING CONTACTS OF DIFFERENT PLUG SYSTEMS.
6113... REPAIRING AIRBAG LEADS (BUILD DATE/VERSION AFFECTED 04/2008 TO 07/2008)
Notes
modules and pyrotechnical belt pretensioners.
Improper handling can lead to triggering of the pyrotechnical seat belt
pretensioner or side airbag, resulting in injuries.
Switch off ignition!

2007 BMW 335i
IMPORTANT: Always use repair cable set for belt tensioner and seat airbag in event of a fault
on driver's and front passenger sides.
 Move driver's seat/front passenger seat fully back and upwards.
Disconnect plug (2).
Fig. 132: Identifying Plug Connections And Plug

Release cable tie (1).
Unlock cap (2) on both sides and pull out in direction of arrow.
Installation:
Secure wiring harness for strain relief with cable tie on plug housing.
2007 BMW 335i
Fig. 133: Pulling Out Cap

Fig. 134: Identifying Cables Insulation

Strip insulation (1) and disconnect cables in accordance with table.
DRIVER'S SEAT PINS REFERENCE CHART

Driver's seat:
2007 BMW 335i
Pin 16 Yellow/Red GSF+

Pin 17 Yellow/Brown GSF-
Pin 18 Yellow SIAVL+ for LHD
Blue SIAVR+ for RHD
Pin 19 Brown SIAVL -/VR-
PASSENGER'S SEAT PINS REFERENCE CHART

Passenger's seat:
Pin 16 Blue/Red GSBF+
Pin 17 Blue/Brown GsBF-
Pin 18 Blue SIAVR+ for LHD
Yellow SIAVL+ for RHD
Pin 19 Brown SIAVR -/VL-
Cut cable (1) with BMW-recommended cable stripper and strip insulation.
A. Dimension A = 11 cm
Fig. 135: Cutting Cable Using BMW-Recommended Cable Stripper

Cut repair cable (1) with BMW-recommended cable stripper and strip insulation.
Cut repair wiring harness 11 cm.
A. Dimension A = 11 cm
2007 BMW 335i
Fig. 136: Identifying Repair Cable

Connect repair cable (1) with butt connector to vehicle wiring harness.
 Universal matrix 61 4 328

 Pliers 61 4 321
Fig. 137: Connecting Repair Cable With Butt Connector To Vehicle Wiring Harness
Slide SHRINK-ON HOSES (1) over ignition circuit leads (2).
IMPORTANT: Do not burn shrink-on sleeve.
With hot-air blower, shrink the shrink-on hose on both sides of shrink-on hose until glue emerges uniformly all
round.
2007 BMW 335i
Fig. 138: Sliding Shrink-On Hoses Over Ignition Circuit Leads

Connect ignition circuit lead (1) with special tool 61 0 327 from kit 61 0 300 in accordance with table.
Fig. 139: Connecting Ignition Circuit Lead Using Special Tool (61 0 327)
61 13... REPAIRING RIBBON CABLES
 61 1 190
Place ribbon cables (1) in connector housing (2) and close cover (3).
2007 BMW 335i
Fig. 140: Identifying Ribbon Cables, Connector Housing And Close Cover
Place connector housing (1) in tool (2) 61 1 190.
Close tool (2).
Fig. 141: Identifying Connector Housing And Tool

61 13... RETAINING BRACKET
Pull relevant fuse out of fuse block (1).
NOTE: Mark positions when removing fuses.
Pull locking slide (2) out of fuse block (1) as far as it will go.
2007 BMW 335i
Fig. 142: Identifying Locking Slide And Fuse Block

With special tool 61 1 136 or 61 1 137 (ejector), press back arrester hook (3) of appropriate contact and pull out
cable.
Fig. 143: Identifying Arrester Hook

61 13... SOCKET HOUSING (RADIO PLUG), HYBRID SYSTEM MQS/MPQ

Removing MPQ contacts from radio plug:
Press lock (1) in direction of arrow.
Detach secondary lock (2) from radio plug.

2007 BMW 335i
Fig. 144: Identifying Lock And Secondary Lock

Feed special tool 61 1 135 past side of contact.
Press special tool 61 1 135 in direction of arrow.
Pull wire (1) with socket contact out of radio plug (2).
Fig. 145: Identifying Wire, Radio Plug And Special Tool (61 1 135)
Removing MQS contacts from contact carrier:
Press lock (1) in direction of arrow and pull housing (2) out of radio plug.
2007 BMW 335i
Fig. 146: Identifying Lock, Housing And Removal Direction

Press lock (1) in direction of arrow. Pull contact carrier (2) out of housing (3).
NOTE: When the contact carrier is pulled out, the secondary locks of the socket
contacts are raised.
Fig. 147: Identifying Lock, Contact Carrier, Housing And Removal Direction
NOTE: The illustration shows an 8-pin socket housing where removal of the contacts is
identical.
2007 BMW 335i
Fig. 148: Identifying Retaining Hook, Secondary Lock And Removal Direction
Hold down arrester hook in secondary lock (1) again. Pull wire with socket contact (2) out of contact carrier (3).
Fig. 149: Identifying Secondary Lock, Socket Contact, Contact Carrier And Removal Direction
Removing MPQ contacts from contact carrier:
Remove contact carrier (1) with MQS contacts from radio plug.
Raise lock (2) on radio plug.
Pull contact carrier (3) out of radio plug.

2007 BMW 335i
Fig. 150: Identifying Lock And Contact Carrier

Press lock (1) in direction of arrow.
Pull secondary lock (2) in direction of arrow completely out of contact carrier (3).
Fig. 151: Identifying Lock, Secondary Lock, Contact Carrier And Removal Direction
Press special tool 61 1 135 on inside of contact into contact carrier (2).
Pull wire with socket contact (1) out of contact carrier (2).
2007 BMW 335i
Fig. 152: Identifying Special Tool (61 1 135), Socket Contact, Contact Carrier And Tool Insertion
Direction
6113... SOCKET HOUSING 42-, 43-PIN, HYBRID SYSTEM MQS/MPQ
Manufactured by AMP: The following contact types without strand sealing can be fitted in the socket
housings:

Open secondary locks (1) on socket housing.
Press back retaining hook of MQS contacts (2) with special tool 61 1 134 and pull out cable with contact.
Press back retaining hook of MPQ contacts (3) with screwdriver or similar tool and pull out cable with contact.
Fig. 153: Pressing Back Retaining Hook Of MPQ Contacts Using Special Tool (61 1 134)
2007 BMW 335i
Installation:
Bend open retaining hook of contacts gently before inserting into plug housing.
To install contacts, observe cavity numbers on reverse side of socket housing.
Fig. 154: Identifying Cavity Numbers On Reverse Side Of Socket Housing

6113... SOCKET HOUSINGS, 2X21-, 2X27-PIN, HYBRID SYSTEMS MQS/MPQ, ELO/ELO-POWER
Manufactured by AMP: The following contact types without strand sealing can be fitted in the socket
housings:

Manufactured by Siemens: The following contact types without strand sealing can be fitted in the socket
housings:
 Elo (electronic contact)

 Elo-Power 2.8 mm wide (electronic contact for heavy loads)
 Elo-Power 5.2 mm wide (electronic contact for heavy loads)
Raise lock (1) on housing (2).
Push contact carrier (3) from rear out of housing.
NOTE: The second contact carrier is pushed out in the same way.
Pushing out the contact carrier releases the secondary locks of the socket
contacts.
2007 BMW 335i
Fig. 155: Pushing Contact Carrier From Rear Out Of Housing

Fig. 156: Pulling Wire With Socket Contact

2007 BMW 335i
Fig. 157: Pulling Cable With Socket Contact Out Of Contact Carrier
6113... SOCKET OF TAB CONNECTOR HOUSINGS
Unlock hooks (1) with special tool 61 1 360 and push plug housing out of the socket.
Fig. 158: Unlocking Hooks Using Special Tool (61 1 360)

61 13 SPECIAL TOOLS FOR WIRING HARNESS REPAIRS
 12 1 080
 61 0 200
 61 0 210
 61 0 220
 61 0 230
2007 BMW 335i
 61 0 300
 61 0 400
 61 1 190
 61 4 320
 61 9 041
 61 9 044
SI 2 04 07 341
Release and press-out tool:

 Special tool 61 0 400 (MINI N12/N14)
Handling:
 Opening plug housings and removing contacts of different plug systems
Fig. 159: Identifying Special Tool Kit

Cutting To Length And Stripping Insulation From Cables:
Handling:
 Cutting To Length And Stripping Insulation From Cables

2007 BMW 335i

Crimping stop parts (small contacts):

1. Tool without crimping head
2. Crimping head (STRIPPING INSULATION AND CUTTING FIBRE-OPTIC CABLES TO
LENGTH)
3. Crimping head (CRIMPING OPTICAL FIBRES)
4. Crimping head (CRIMPING MICRO QUADLOCK SYSTEM CONTACTS (MQS))
5. Crimping head (CRIMPING MICRO POWER QUADLOCK CONTACTS (MPQ))
6. Replacement blade (face-cutting fibre-optic cables)
7. Replacement blade with tool (insulation stripping unit)
8. Universal crimping head
Fig. 161: Identifying Crimping Stop Parts (Small Contacts)

Crimping stop parts (large contacts):

2007 BMW 335i
 Special tool 61 0 200 (crimping set)

 Special tool 61 0 210 (matrix set LSK 8)
 Special tool 61 0 220 (matrix set SLK 2.8)
 Special tool 61 0 230 (matrix set MAK 8 / DFK4)
Fig. 162: Identifying Crimping Stop Parts (Large Contacts)

Crimping antenna elbow plugs:
 Special tool 61 9 041 (hand crimping tool)

 Special tool 61 9 044 (matrix)
Handling:
 Antenna elbow plug on radio receiver
Fig. 163: Identifying Special Tool (61 9 044) And (61 9 041)
Repair kit for ignition cables and for crimping fan connector receptacles 4 mm 2 :
2007 BMW 335i
Handling:
 Crimping Stop Parts (Contacts)
Fig. 164: Identifying Repair Kit For Ignition Cables

Repairing ribbon cables:
Handling:
 Repairing Ribbon Cables

61 13... TREATING CABLES AND FIBRE-OPTIC CABLES

2007 BMW 335i
 61 1 190
 61 4 320
SPECIAL TOOLS CHART

Repair range for vehicle electrical system
Crimping set with tool for fibre-optic cables, Micro 61 4 320
Power Quadlock (MPQ), Micro Quadlock System
(MQS) contacts and universal crimping head
Insulation displacement tool for ribbon cable 61 1 190
Subject of repair instructions
 SPECIAL TOOLS FOR WIRING HARNESS REPAIRS

 CUTTING TO LENGTH AND STRIPPING INSULATION FROM CABLES
 CRIMPING STOP PARTS (CONTACTS)
 BUTT CONNECTOR FOR REPAIRING A PLUG CONNECTION
 FAN CONNECTOR FOR RETROFITTING/REPAIRS
 Aerial elbow plug on radio receiver
 CUTTING TO LENGTH AND STRIPPING INSULATION FROM OPTICAL FIBERS
 CRIMPING OPTICAL FIBRES
 Insulation displacement connector for REPAIRING RIBBON CABLES
61 13 050 REMOVING AND INSTALLING/REPLACING INTERIOR FUSE BOX
 Remove Flap In Luggage Compartment Panel on right

 Remove battery cover
 Disconnect Negative Battery cable
 Remove right Glovebox with housing
 Remove Junction Box
Release screws (1).
Disconnect plug connector (2).
For tightening torque refer to 61 13 1AZ. in 61 13 FUSE BOX

2007 BMW 335i
Remove battery positive lead from fuse box.
Installation:
Make sure positive battery cable is correctly seated on fuse box.
Fig. 166: Identifying Cap, Plug Connector And Screw

Detach plug connectors (1) from back of fuse box (2).
NOTE: Write down colors and positions of plug connectors before removing.
Replacement:
Remove fuses and relays.
Fig. 167: Identifying Plug Connectors And Back Of Fuse Box

DISTRIBUTION BOX, POWER SUPPORT POINTS

2007 BMW 335i
61 42... REMOVING AND INSTALLING/REPLACING DC/DC CONVERTER
NOTE: DC/DC converter in vehicles with automatic start-stop function.

There are two versions:
 Without additional bracket for diesel engine vehicles

 With additional bracket for gasoline engine vehicles
Depending on the equipment, one or both versions are installed in the M3
IMPORTANT: Read and comply with INFORMATION ON PROTECTION AGAINST DAMAGE

FROM ELECTROSTATIC DISCHARGE.
Remove LOWER SECTION OF MICROFILTER HOUSING (all except M3)
Remove right upper section of microfilter housing M3
Remove cover (3).
Fig. 168: Removing Locks

Diesel engine vehicles (without additional bracket):
Release lugs in direction of arrow. Remove DC/DC converter (1) by pulling upward. Disconnect plug
connection (2).
2007 BMW 335i
Fig. 169: Releasing Lugs (Diesel Engine Vehicles)

Gasoline engine vehicles (with additional bracket):
Release lugs in direction of arrow. Remove DC/DC converter (1) by pulling upward. Disconnect plug
connection (2).
Fig. 170: Releasing Lugs (Gasoline Engine Vehicles)

M3:
Release tabs in direction of arrow and remove DC/DC converter with additional bracket (1) upward. Disconnect
plug connection (2).
Release tabs in direction of arrow and remove DC/DC converter without additional bracket (3) upward.
2007 BMW 335i
IMPORTANT: Do not mix up plug connections (2, 4)!
Fig. 171: Releasing Tabs

61 14... REMOVING AND INSTALLING/REPLACING ENGINE COMPARTMENT B+ TERMINAL
 Remove Electronics Box
Remove cable lug mounting from positive battery leads.

2007 BMW 335i
Fig. 172: Identifying Cable Cap

Remove cover (1).

Unscrew nuts (1).
Remove positive leads.
Release lock (2).
Remove B+ terminal with frame (3).
Installation:
Frame (3) must snap correctly into B+ terminal.

2007 BMW 335i
Fig. 174: Identifying Lock, Frame And Nuts

61 14 010 REMOVING AND INSTALLING/REPLACING DISTRIBUTION BOX (ON BATTERY)
 Disconnect Negative Battery Cable
Release screws (1) and remove bracket (2).
Fig. 175: Identifying Screws And Bracket

Fold up covers (3).
Unscrew nuts (2).
Fold up covers (5).
Unscrew nuts (4).

2007 BMW 335i
Fig. 176: Identifying Plug Connection, Covers And Nuts

Using a screwdriver, expand locking bracket (1) at lower end and clip out.
Remove distribution box (2) towards top.
Fig. 177: Identifying Distribution Box, Bracket And Removal Direction

BATTERY
61 20... THRESHOLD VALUES FOR BATTERY INSPECTION OF ALL BATTERY (TELEPHONE
EXCEPT FOR TELEPHONE BATTERY)
Safety Instructions For Handling Vehicle Battery.
Test step 1 - before charging the battery
BATTERY SPECIFICATION
Charge state (1) Starting capability (2) Test result
Not testable Charge
2007 BMW 335i
less than 50 % (2) Charge

more than 50 % less than 75 % Charge
more than 50 % more than 75 % (3) Charge
more than 80 % more than 75 % O.K.
(1) Charge condition and starting power must always be evaluated together
(2) When test charging for more than 5 hours, use charger Gossen CG 32 or Siemens / Gossen VB 801
(3) Fully charge until charge state is more than 80 %.
Test step 2 - after charging the battery
BATTERY CHARGING CHART

Charge condition (1) Starting capability (2) Test result
Not testable Defective
less than 50 % less than 75 % Charge
more than 50 % more than 75 % Charge
(2) When test charging for more than 5 hours, use charger Gossen CG 32 or Siemens / Gossen VB 801
NOTE: If battery was checked on the positive terminal in the engine compartment,
repeat check directly on battery for sake of safety.
61 20... AGM BATTERY

2007 BMW 335i
Fig. 178: Identifying AGM Battery

Introduction
In September 2002 so-called VRLA batteries, better known as AGM batteries , were introduced. (VRLA
stands for V alve R egulated L ead A cid, i.e. lead acid battery with pressure relief valve; AGM stands for A
bsorbent G lass M at, i.e. absorbent glass fibre fleece)
AGM batteries are fitted in models with electrical loads/consumers which have a high energy demand.
With the option SA 146 (2nd battery), the AGM battery (70 Ah) is fitted as the 2nd battery.
The constantly increasing energy demand of modern vehicle electrical systems calls for ever more powerful
battery solutions. Today, up to 100 servomotors, which have to be electrically powered, operate in a modern
luxury-class motor vehicle. Added to these are safety, environmental and comfort and convenience elements
which are increasingly becoming standard features, such as e.g. Anti-lock Brake System (ABS), Dynamic
Stability Control (DSC), electric steering effort assistance (EPS), heated catalytic converter, electronic chassis
and suspension control, air conditioning and navigation system.
The power consumption is considerable even when the vehicle is parked.
The somewhat higher price compared with a battery of similar size is fully balanced by the following benefits:
 Significantly longer service life

 Increased starting reliability at low temperatures
2007 BMW 335i
 Safe starting of engines with high starting current demands, e.g. high-performance diesel engines
 100 % freedom from maintenance
 Low risk in event of an accident (reduced risk to the environment)
Service life of AGM battery
Fig. 179: AGM Battery Service Life Graph

Unlike the previously used lead calcium batteries, the sulfuric acid contained in batteries with fleece technology
is not self-contained in the battery housing.
Instead, the sulfuric acid is 100 % bound up in glass fibre fleece mats (separators). Thus, no acid can escape if
the battery housing is damaged. In addition, the AGM battery is sealed gas-tight. This is possible because the
gases are converted back into water as a result of the separator permeability.
Brief description of components
An AGM battery can be recognized by its black housing and the lack of a so-called "Magic Eye".
2007 BMW 335i
Fig. 180: Identifying AGM Battery Components

Design
The AGM battery differs from the conventional lead calcium battery as follows:
 Larger plates:
Larger plates provide for a 25 % higher power density.
 Separators made of glass fibre fleece:
These provide for up to 3 times higher cycle reliability.
This in turn improves cold starting performance, current consumption and service life.
 Gas-tight housing with pressure relief valve (see also mode of operation):
The cell plugs are welded and cannot be opened.
 Acid bound up in the glass fibre fleece:

2007 BMW 335i
The acid is not as previously self-contained in the housing, but 100 % bound up in the glass fibre fleece.
This provides increased protection against acid leakage and thus represents a reduced risk to the
environment.
Mode of operation
The AGM battery differs from conventional batteries in its non-polluting and substance-retaining behavior
during charging.
When vehicle batteries are charged, the two gases oxygen and hydrogen are released by electrolysis.
 In a conventional wet lead calcium battery, the two gases hydrogen and oxygen are dissipated into the
atmosphere.
 In an AGM battery, the two gases are converted back into water: The oxygen which is created at the
positive electrode during charging passes through the permeable glass fibre fleece to the negative
electrode. At the negative electrode the oxygen reacts with the arriving hydrogen ions in the electrolyte to
form water (oxygen cycle).
In this way, the gas and thus also the electrolyte are not lost.
Only in the event of an excessively heavy buildup of gas, i.e. excessively high pressure buildup (20 to 200
mbar), does the pressure relief valve discharge the gas. In this process, the pressure relief valve does not allow
any oxygen in the air to enter. Because a valve regulates the pressure in the battery, the AGM battery is also
known as a VRLA battery (Valve Regulated Lead Acid).
Notes and instructions for service personnel
It is necessary when handling an AGM battery to observe some particular points pertaining to battery changing
and installation location.
Charging
WARNING: Do not charge the AGM battery with = 15.2 V. No quick-charging routines!
When charging removed batteries (so-called stand-alone batteries), do not exceed the maximum charging
voltage of 15.2 V at room temperature. Also when charging via the jump start terminal, do not exceed the
maximum charging voltage of 15.2 V at room temperature.
The AGM battery will be damaged even when it is only briefly charged with a charging voltage of more than
15.2 V. A charging voltage of more than 15.2 V is usually used in quick-charging routines.
Installation location
WARNING: Do not install the AGM battery in the engine compartment.

2007 BMW 335i
The AGM battery must not be installed in the engine compartment on account of the high spatial temperature
differences, otherwise its service life will be significantly shortened.
Housing
WARNING: Do not open the AGM battery.
The AGM battery must not be opened under any circumstances as the introduction of oxygen from the air will
cause the battery to lose its chemical equilibrium and be rendered non-operational.
Battery changing
Any conventional lead calcium battery can always be replaced by an AGM battery.
Using an AGM battery does not require any alterations to be made to the vehicle electrical system.
NOTE: The AGM battery is recommended for "problem customers".
"Problem customers" encounter a high energy throughput through their batteries. This high energy throughput is
caused by stationary loads/consumers (TV, independent heating, etc.) and a bad use profile for the battery
("chauffeur operation", short-distance driving, "stop-and-go"). The use of an AGM battery is recommended for
these problem customers.
6100... BATTERY
NOTE: Important notes and instructions for handling batteries in the dealership can be
found in:
 DISCONNECTING BATTERY
 BATTERY CHARGING
 NOTES/INFORMATION ON START ASSISTANCE (JUMP STARTING)
Battery care and maintenance
In low-maintenance batteries, check the acid level at least once a year. If necessary, top up with distilled water
up to the top marking.
The increasing number of electronic control units in the car reduces the self-discharging time of the battery
(even in standby mode). To maintain the battery service life and to avoid exhaustive discharging, recharge laid-
up vehicles every 6 weeks at the latest. The time for self-discharging depends on vehicle type and equipment
specification.
Battery test
The battery acid density can be used to measure the charge state. However this test produces uncertainty caused
2007 BMW 335i
by a design-related range of variation. The acid density e.g. for a charged battery is 1.28 kg/l (in the tropical
version the acid density is 1.23 kg/l).
Another interference factor is the acid lamination immediately after filling with distilled water.
Battery wear with partially sulfated and/or heavily contaminated plates will also lead to incorrect acid density
test results.
61 20... BATTERY CHARGING
If a normal or quick charger is used to charge the battery, the battery must be disconnected from the vehicle
electrical system and removed. This prevents damage to paintwork and upholstery.
IMPORTANT: In order to prevent the intelligent battery sensor from malfunctioning, the
charging terminals in the engine compartment must be used without fail in
vehicles from E60 and should be used if possible in other vehicles.
IMPORTANT: Before charging the battery while it is installed, first carry out a Closed-Circuit
Current Test. If here the voltage is 10 V or less, one or more of the cells may be
faulty or the entire battery may already be damaged. In this case, always
remove the battery as escaping gases during charging could damage the
interior equipment and trim. Attempt to regenerate faulty cells with low
charging current.
If necessary, open existing plugs on the individual cells.
61 20... BATTERY OPEN-CIRCUIT CURRENT TEST
NOTE: Observe Safety Instructions for handling vehicle battery.
Observe Service Information Adapter for open-circuit current measurement.

2007 BMW 335i
Fig. 181: Identifying Battery Open-Circuit Current Test Equipment

The open-circuit current test is performed using the Diagnosis and Information System (DIS).
6120... BATTERY REPLACEMENT INFORMATION
A vehicle battery is constructed for the installation location and the individual power requirements of the
particular vehicle. These individual power requirements depend on the motorization and different types of
optional equipment. The individually assigned vehicle battery is the ideal compromise between the power
requirements of the vehicle electrical system and the weight and service life of the vehicle battery.
Vehicles with the automatic engine start-stop function or particular motorization and optional equipment are
equipped with a special vehicle battery (AGM battery), since only this battery type can provide elevated power
requirements over the extended service life. Installing a different vehicle battery can cause problems with
vehicle electronics, can reduce functions or can cause leakage of battery acid.
In the event of an accident where the airbags are deployed in vehicles with a vehicle battery in the luggage
compartment, the electrical connection between the vehicle battery and the trigger is automatically disconnected
through pyrotechnics. This prevents a possible short circuit.
Proper operation of all of these safety and convenience functions requires a battery that conforms with
specifications and that is properly registered in vehicles with energy management systems (IBS, power module).
Vehicles with energy management systems (IBS, power module): Register battery replacement
2007 BMW 335i
The vehicle electrical system is informed about the vehicle battery characteristic data, such as type, size, age
and current power capacity. Therefore, only one work scope will be provided that is permitted by the current
status of information.
When installing a new vehicle battery, the battery must be registered and thus must also be registered with the
vehicle electrical system.
Diagnosis system:
Register battery replacement
 Service functions
 Body
 Voltage supply
 Register battery replacement
 Test plan
When retrofitting, a more powerful battery may be used. Standard batteries may always be replaced by AGM
batteries with the same specifications.
When installing a battery of a different size or a different battery type, this change in vehicle data must be
programmed into the vehicle data in accordance with specifications.
Programming system:
 Battery retrofitting
61 20 900 DISCONNECTING AND CONNECTING BATTERY NEGATIVE LEAD
Follow Instructions for disconnecting and connecting battery
IMPORTANT: Do not under any circumstances use force to pull/lever off Intelligent Battery
Sensor (IBS).
 Remove Battery Cover Or Open Right Luggage Compartment Trim Panel
Loosen nut (1).
Disconnect battery negative lead (3) and secure at side.

2007 BMW 335i
Fig. 182: Identifying Battery Negative Lead And Nut

61 12... GENERAL INFORMATION ON INTELLIGENT BATTERY SENSOR (IBS)
NOTE: Do not connect continuous trickle charger to the cigarette lighter.
The cigarette lighter is powered by the rear distribution box via a relay. This relay drops out after terminal 15
OFF. This means that a continuous trickle charger connected to the cigarette lighter is disconnected from the
battery.
Charge the battery via the jump-start connection points. Only then can the power supply be registered by the
vehicle.
WARNING: Danger of destruction in event of mechanical strain
 Do not introduce any additional connections at the battery negative

terminal.
 Do not modify the grounding cable.
The grounding cable also serves to dissipate heat.
 Do not establish any connection between the IBS and the sensor
screw.
 Do not use force when disconnecting the pole shoe from the battery
terminal:
 Do not pull on the grounding cable.
 Do not place any tools under the IBS to lever off the pole shoe.
 Do not use IBS connections as levers.

 Use a torque wrench and set tightening torque in accordance with
repair instructions.
 Do not release or tighten down sensor screw (screw with Torx head).
2007 BMW 335i
 Avoid contact between IBS and ground.
WARNING: Danger of destruction to IBS and cables when battery is replaced
 The IBS and the cables can be destroyed by mechanical strain when
the battery is replaced.
Therefore avoid mechanical strain.
 The size (capacity) of the battery required for the car is coded in the
Car Access System (CAS).
 Use the battery size (capacity) installed as standard when replacing
the battery.
 Register battery change via Service Function (Progman or DIS).
 Delete fault entries in the Digital Engine Electronics (DME)
associated with battery replacement.
 Always proceed in accordance with the repair instructions.
NOTE: Battery draining possible in spite of the intelligent battery sensor IBS being
fault-free.
 A battery can be drained (e.g. with lights or radio switched on) even when the IBS functions perfectly in
conjunction with power management.
 For this reason, only replace the IBS when a corresponding fault is entered in the DME or DDE.
61 20 908 PERFORMING BATTERY "POWER RESET" (FOR PROGRAMMING/CODING

CONTROL UNIT(S))
IMPORTANT: Observe Safety Instructions for handling vehicle battery.
The following steps must be carried out for a "power reset":
 Switch off and disconnect battery charger

Cars with ignition key: Turn ignition key to 0 position
Cars with identification sensor: Remove identification sensor from slot
Cars with comfort access system: Make sure terminal is in 0 position
 Disconnect battery negative terminal

 Reconnect battery negative terminal (to ensure bus activity)
2007 BMW 335i
 Waiting time (5-10 seconds)

 Waiting time (1 minute)
 Connect battery negative terminal and tighten, for tightening torque refer to 61 21 1AZ in 61 21
BATTERY WITH TERMINAL .
 Connect and switch on battery charger
 Switch ignition on
61 00... SAFETY INSTRUCTIONS FOR HANDLING VEHICLE BATTERY
See SAFETY INSTRUCTIONS FOR HANDLING VEHICLE BATTERY.
6120... THRESHOLD VALUES FOR ASSESSMENT OF ALL BATTERIES (EXCEPT TELEPHONE

BATTERIES)
See SAFETY INSTRUCTIONS FOR HANDLING VEHICLE BATTERY.
Test step 1 - before charging the battery
SAFETY INSTRUCTIONS FOR HANDLING VEHICLE BATTERY (BEFORE CHARGING)

Charge state(1) Starting capability(2) Test result
Not testable Charge
less than 50 %(2) Charge
more than 50 % less than 75 % Charge
more than 50 % more than 75 %(3) Charge
more than 80 % more than 75 % O.K.
(2) When test charging for more than 5 hours, use charger Gossen CG 32 or Siemens/Gossen VB 801
(3) Fully charge until charge state is more than 80 %.
Test step 2 - after charging the battery
SAFETY INSTRUCTIONS FOR HANDLING VEHICLE BATTERY (AFTER CHARGING)

Charge condition(1) Starting capability(2) Test result
Not testable Defective
less than 50 % less than 75 % Charge
more than 50 % more than 75 % Charge
(2) When test charging for more than 5 hours, use charger Gossen CG 32 or Siemens/Gossen VB 801
2007 BMW 335i
NOTE: If battery was checked on the positive terminal in the engine compartment,
repeat check directly on battery for sake of safety.
61 20 503 VEHICLE BATTERY - CLOSED-CIRCUIT CURRENT MONITORING
To access negative lead of battery, perform the necessary preliminary work described in DISCONNECTING
AND CONNECTING BATTERY NEGATIVE LEAD.
Do not disconnect negative lead of battery.
Connect BMW diagnosis system.
Connect clip-on probe to negative lead of battery. The arrow on the current clamp must point towards the
battery.
Measure closed-circuit current.
61 00. VERSION WITH AFS (ACTIVE FRONT STEERING): SETTING STEERING ANGLE (AFTER
RECONNECTING VEHICLE BATTERY)
See VERSION WITH AFS (ACTIVE FRONT STEERING): SETTING STEERING ANGLE (AFTER
RECONNECTING VEHICLE BATTERY).
BATTERY/VAPOR SEPARATOR
61 21 010 REMOVING AND INSTALLING OR REPLACING BATTERY
Notes and instructions on Intelligent Battery Sensor IBS .
IMPORTANT: Do not under any circumstances pull/lever safety battery terminal off by force.
Battery crash element must be reinstalled!
 On vehicles from build date 12/2006 or when IBS is replaced since

12/2006, battery crash element has been removed without replacement
(IBS2006 replaces IBS2004 from 12/2006 IBS2004)
 Remove Flap in luggage compartment panel on right

 Remove Distribution Box
2007 BMW 335i
Unlock positive terminal cover (1).
Slacken nut (2) of safety battery terminal (3).
Detach safety battery terminal (3) towards top, lay to one side and secure.
Fig. 183: Identifying Positive Terminal Cover, Nut And Safety Battery Terminal
Detach vent (1) in direction of arrow.
Release threaded pin (2) and remove holder with battery crash element (3).
Fold back both bar fasteners (4) and pull battery towards rear out of associated fixture.
Lift out battery.
Fig. 184: Identifying Vent, Battery Crash Element, Bar Fasteners And Removal Direction
Installation:
2007 BMW 335i
Make sure battery is correctly seated in associated fixture.
Replacing version with intelligent battery sensor (IBS):
 Register battery replacement

 Read out fault memory, clear if necessary
SWITCH
61 31... OVERVIEW OF SWITCHES (COUPE)
Fig. 185: Overview Of Switches (Coupe)

61 31... OVERVIEW OF SWITCHES (CONVERTIBLE)

2007 BMW 335i
Fig. 186: Overview Of Switches (Convertible)

6131195 REMOVING AND INSTALLING (REPLACING) FRONT CONTROLLER (FROM 09/2008)

Before dismantling it make absolutely sure, whether the controller is installed
with the status before or after Life Cycle Impulse (LCI).
NOTE: The number of buttons and shape of controller can vary depending on vehicle
type.
Before LCI: Controller (1) has buttons on bottom only.
After LCI: Controller (2) has buttons top and bottom.
NOTE: These repair instructions describe the removal and installation (replacement) of
controller (2)!
2007 BMW 335i
Fig. 187: Locating Controller Buttons


The button for the controller must not be removed!
 Remove TRIM FOR STORAGE TRAY
Carefully raise catches (1) on controller holder (3) and remove controller (2) towards top.
Installation:
Make sure controller (2) is correctly engaged in controller holder (3).

2007 BMW 335i
Fig. 188: Identifying Controller And Catches On Controller Holder

Replacement
Carry out PROGRAMMING/ENCODING.
6131038 REMOVING AND INSTALLING (REPLACING) SWITCH FOR PASSENGER AIRBAG

DEACTIVATION
modules and pyrotechnical belt pretensioners.
 Disconnect BATTERY NEGATIVE LEAD

 Remove SIDE COVER ON INSTRUMENT PANEL
Unlock catches (1) and feed out switch for passenger airbag deactivation (2) to front of cover.
Installation:
Make sure switch for passenger airbag deactivation (2) is correctly seated in cover.
Fig. 189: Identifying Catches And Switch For Passenger Airbag Deactivation
Installation instructions for replacement only for E63/E64 with production date up to 01/2010:
A groove must be filed in the trim at location (1).

2007 BMW 335i
Fig. 190: Identifying Groove In Trim

Replacement:
Remove LOCK CYLINDER FOR PASSENGER AIRBAG DEACTIVATION .
61 31 006 REMOVING AND INSTALLING (REPLACING) FIXTURE FOR STEERING COLUMN

STALK
WARNING: Move wheels in to straight-ahead position and do not alter this position
during the repair work.
 Remove Steering Wheel

 Remove Top Section Of Steering Column Casing.
 Remove Lower Section Of Steering Column Trim
Release screws (1).
Pull back fixture for steering column switch (2) in direction of arrow.
Disconnect plug connections behind and remove fixture for steering column stalk (2).
Installation:
Carry out Steering Angle Sensor Adjustment.
On vehicles with active front steering, steering angle sensor adjustment is performed by means of Initial
Operation / adjustment of active front steering.
2007 BMW 335i
Fig. 191: Identifying Steering Column Switch, Screws, Steering Column Stalk And Removal Direction
Replacement:
 Remove Volute Spring Cassette

 Carry out Vehicle Programming/Coding
NOTE:  If replacement of the steering column switch cluster is initiated via

Progman, the steering column switch cluster is coded indirectly via
the DSC control unit
 If coding is cancelled, first adjust the steering angle sensor; this
makes a brand-new steering column switch cluster coding-
compatible again if necessary
 Then code the DSC control unit again
 Carry out Steering Angle Sensor Adjustment
NOTE:  If steering angle sensor adjustment is cancelled, first code the DSC
control unit
 Then adjust the steering angle sensor again
 Vehicles with active front steering:

 Steering angle sensor adjustment is performed by means of Initial Operation / Adjustment of
active front steering
 If necessary, proceed in accordance with instructions
61 31 008 REMOVING AND INSTALLING/REPLACING STEERING-COLUMN SWITCH CLUSTER
Move wheels into straight-ahead position and do not alter this position during the repair work.
Do not under any circumstances turn the steering column switch cluster when the steering wheel is removed.
2007 BMW 335i
 Remove steering wheel

 Remove STEERING COLUMN SHROUD LOWER SECTION
 If necessary, remove switch for steering column adjustment
WARNING: Do not twist the coil spring cassette (1)!
NOTE: The COIL SPRING CASSETTE (1) may be replaced separately, if necessary!
Fig. 192: Identifying Coil Spring Cassette


2007 BMW 335i
Release screws (1).
Remove steering-column switch cluster in direction of arrow.
Installation note:
The steering column switch cluster is installed in reverse sequence.
Carry out steering angle sensor adjustment.
Fig. 194: Removing Steering-Column Switch Cluster

Replacement:
 Remove volute spring cassette

 Carry out VEHICLE PROGRAMMING/ENCODING
NOTE:  If replacement of the steering column switch cluster is initiated via

Progman, the steering column switch cluster is coded indirectly via
the DSC control unit
 If coding is cancelled, first adjust the steering angle sensor; this
makes a brand-new steering-column switch cluster coding-
compatible again if necessary
 Then code the DSC control unit again
 Carry out steering angle sensor adjustment

2007 BMW 335i
NOTE:  If steering angle sensor adjustment is cancelled, first code the DSC
control unit
 Then adjust the steering angle sensor again
 Vehicles with active steering:

 Steering angle sensor is adjusted by means of INITIAL OPERATION / ADJUSTMENT of
active front steering
 If necessary, proceed in accordance with instructions
61 31 009 REPAIRING STEERING COLUMN SWITCH CLUSTER (SZL)
WARNING: Move wheels into straight-ahead position and do not alter this position
IMPORTANT: Read and comply with notes on PROTECTION AGAINST ELECTROSTATIC

DISCHARGE (ESD PROTECTION).
 Remove VOLUTE SPRING CASSETTE

 Spread antistatic mat
 Use antistatic wrist trap with connecting line
Note on ordering:
 Workshop equipment
 Workshop equipment catalogue
 Order number
61 31 9 141 875
IMPORTANT: Extreme cleanliness is required!
NOTE: Installation is described separately.
Removal
 Unlock retaining lugs on upper housing section (1) with a suitable tool.
 Remove upper housing section.
2007 BMW 335i
Fig. 195: Locating Retaining Lugs On Upper Housing Section

 Release screws (1) in optical element (2).
IMPORTANT: Touch only the optical element.
NOTE: After removal, render optical element unusable and dispose of it in the
appropriate manner.
Fig. 196: Identifying Optical Element With Screws

2007 BMW 335i
Fig. 197: Removing Encoded Disc From Rear Of Steering Column Switch Cluster Using Plastic Tube
Unclip encoded disc (1) from rear of steering column switch cluster with plastic tube (2) supplied for the
purpose.
In this process, hold encoded disc by inserting two fingers in the hole.
2007 BMW 335i
Fig. 198: Tilting Encoded Disc Away From Printed Circuit Board When Removing
To prevent damage, tilt encoded disc (1) away from the printed circuit board when removing.
IMPORTANT: It is not permissible to clean the bearing points.
IMPORTANT: Make sure that encoded disc, optical element and printed circuit board do not
come into contact with grease.
Apply grease supplied for the purpose to friction face (1) of bearing race of front of steering column switch
cluster.
2007 BMW 335i
Fig. 199: Identifying Bearing Race Friction Face

Installation
IMPORTANT: Thoroughly clean your hands before installation.
Before installing the new parts, put on gloves and hair net included in the
repair kit!
2007 BMW 335i
Fig. 200: Precautions For Installing New Parts

IMPORTANT: Not permitted!
 Do not touch encoded disc (1) with your fingers!

 Do not touch printed circuit board (2)!
 Do not apply pressure to encoded disc (3)!
 Do not touch sides of encoded disc (4)!
 Hold encoded disc (1) by inserting two fingers in the hole.
 Position encoded disc centered in fixture and clip it in.
 Turn encoded disc to and front to spread the grease over the friction face
2007 BMW 335i
Fig. 201: Holding Encoded Disc By Inserting Two Fingers In Hole

Fig. 202: Assembling Optical Element From Individual Parts Included In Repair Kit
Assembly optical element (1) from individual parts included in the repair kit.
2007 BMW 335i
 Secure optical element (2) with screws (1).

 Tightening torque: 0.26 Nm.
Fig. 203: Identifying Optical Element With Screws

 Clip upper housing section (1) into place.

 After inserting coil spring cassette, affix "CDS" label close to part-number label (2).
Installation note:
Make sure retaining lugs are correctly engaged.
Fig. 204: Identifying Upper Housing Section And Part-Number Label

2007 BMW 335i
Installation note:
Mark (1) and mark (2) must point to each other.
Fig. 205: Identifying Alignment Marks

Carry out STEERING ANGLE SENSOR ADJUSTMENT.
Carry out vehicle programming and encoding.
61 31 011 REMOVING AND INSTALLING/REPLACING VOLUTE SPRING CASSETTE
WARNING: Move wheels in to straight-ahead position and do not alter this position
 Remove Fixture For Steering Column Stalk
Unlock catches (1).
Press lock (2) and remove volute spring cassette (4) in direction of arrow from fixture for steering column stalk
(3).
2007 BMW 335i
Fig. 206: Identifying Lock, Volute Spring Cassette, Steering Column Stalk And Removal Direction
IMPORTANT:  Do not turn ring (1).

 Also turning ring (1) through 360° is not permitted!
 Secure ring (1) against unauthorized turning (e.g. with adhesive tape).
Installation:
Notch (3) on ring (1) must line up with arrow (4) on switch (2).
Fig. 207: Identifying Ring, Notch, Arrow And Switch

IMPORTANT: Fit volute spring cassette (1) so that guide (2) can slide exactly into associated
notch on switch (3).
2007 BMW 335i
Fig. 208: Identifying Volute Spring Cassette, Guide And Notch On Switch
61 31 023 REMOVING AND INSTALLING/REPLACING START/STOP SWITCH
Press catches (1) together and unclip Start/Stop switch (2) in direction of arrow.
Fig. 209: Identifying Catches, Start/Stop Switch And Removal Direction

61 31 037 REMOVING AND INSTALLING/REPLACING LIGHT CONTROL UNIT
 00 9 317
 Remove Decorative Strip On Instrument Panel On Left

2007 BMW 335i
Lever out trim of light control unit (2) with special tool 00 9 317 at fastening points (1) and pull back in
direction of arrow.
Unlock and disconnect associated plug connection, remove trim of light control unit (2).
Fig. 210: Identifying Light Control Unit, Fastening Points And Removal Direction
Replacement:
Unlock catches (1) and unclip light control unit (2) from trim (3).
Fig. 211: Identifying Catches, Light Control Unit, Trim And Removal Direction
61 31 043 REMOVING AND INSTALLING OR REPLACING ROOF SWITCH CLUSTER (COUPE)
 00 9 341
2007 BMW 335i
Protection)!
IMPORTANT: Follow instructions for Handling Light Bulbs (Interior Lights).
Carefully lever out roof light trim (1) with special tool 00 9 341.
Reflector underneath must not be damaged.
Fig. 212: Identifying Special Tool (00 9 341), Roof Light Trim And Removal Direction
Retainer (1) is on centerline of reading light.
Carefully unlock both retainers (1) on left/right with special tool 00 9 341.
Reflector (2) and roof liner (3) must not be damaged.
Fig. 213: Identifying Special Tool (00 9 341), Retainers, Reflector, Roof Liner And Removal Direction
Carefully unlock both retainers on left/right with special tool 00 9 341 and lever out roof light (1).
2007 BMW 335i
Disconnect plug connections underneath and remove roof switch cluster (1) from roof liner (2).
IMPORTANT: Disconnecting the plug connection for the hands-free microphone or

emergency SOS call button results in fault memory entries in the telephone
control unit (limitation in the emergency SOS call system).
Fig. 214: Identifying Special Tool (00 9 341), Roof Switch Cluster, Roof Liner And Removal Direction
Installation:
Assemble roof light prior to installation:
 Feed in roof light trim (1) at line (2)

 Press roof light trim (1) in direction of arrow onto roof light (3)
Make sure roof light trim (1) is correctly seated.
Fig. 215: Identifying Roof Light Trim, Line, Roof Light And Installation Direction
2007 BMW 335i
Replacement:
 If necessary, convert bulbs.

 Note Bulb Type
 Initialize Slide/Tilt Sunroof.
61 31 043 REMOVING AND INSTALLING OR REPLACING ROOF SWITCH CENTER

(CONVERTIBLE)
Protection)!
Carefully lever out roof switch center (1) with special tool 00 9 317 and lower slightly.
Fig. 216: Identifying Roof Switch Center With Special Tool

Unlock retaining clips (1) and feed out roof switch center in direction of arrow.
2007 BMW 335i
Fig. 217: Unlocking Retaining Clips

Disconnect plug connections (1) and remove roof switch center.


Replacement:
If necessary, remove bulbs .
Carry out Vehicle Programming/Coding.
61 31 052 REMOVING AND INSTALLING/REPLACING CENTER CONSOLE SWITCH CLUSTER

(WITHOUT CCC/ASK)
Replacement:

2007 BMW 335i
Unclip center console switch cluster (2) at retaining points (4).
Remove center console switch cluster (2) in direction of arrow from trim (3).
Fig. 219: Identifying Plug Connection, Retaining Points, Centre Console Switch Cluster And Trim
61 31 054 REMOVING AND INSTALLING/REPLACING CENTER CONSOLE SWITCH CLUSTER

(WITH CCC/ASK)

Unclip trim (3) at fastening points (1) and (2).
Feed out associated ribbon cable and remove trim (3) complete with center console switch cluster (4).
Fig. 220: Identifying Centre Console Switch Cluster, Trim, Fastening Points And Removal Direction
2007 BMW 335i
Replacement:
Unclip center console switch cluster (1) at fastening points (2) and (4) and remove.
NOTE: Ribbon cable (3) of center console switch cluster (1) leads to heater/air
conditioner operator unit.
Installation:
Make sure center console switch cluster (1) engages correctly in upper fastening points (4) and lower fastening
points (2).
Fig. 221: Identifying Fastening Points, Ribbon Cable, Centre Console Switch Cluster And Removal
Direction
61 31 066 REMOVING AND INSTALLING/REPLACING HOTEL SETTING SWITCH
 64 1 020
 Open glovebox.
Lever hotel setting switch (1) with special tool 64 1 020 in direction of arrow out of glovebox (2).
Disconnect plug connection underneath and remove hotel setting switch (1).
2007 BMW 335i
Fig. 222: Identifying Special Tool (64 1 020), Glovebox And Hotel Setting Switch
61 31 068 REMOVING AND INSTALLING/REPLACING SWITCH FOR PASSENGER AIRBAG

DEACTIVATION
WARNING: Read and comply withSafety Regulations for handling airbag modules
and pyrotechnical belt tensioners.
Incorrect handling can activate airbag and cause in jury.

 Remove Side Cover on right from instrument panel
Unlock catches (1) and remove switch for front passenger airbag deactivation (2) towards front side of cover.
Installation:
Make sure switch for front passenger airbag deactivation (2) is installed in correct position.
Fig. 223: Identifying Front Passenger Airbag Deactivation Switch And Catches
2007 BMW 335i
61 31 078 REMOVING AND INSTALLING/REPLACING SWITCH FOR CONVERTIBLE TOP

OPERATION
Remove trim for storage compartment .
Release screws (1).
Remove switch (2) from trim (3).
Fig. 224: Remove Switch (2) From Trim

61 31 079 REMOVING AND INSTALLING/REPLACING SWITCH FOR HAZARD WARNING

FLASHERS/CENTRAL LOCKING
Unclip switch for hazard warning flashers/central locking (1) in direction of arrow from right instrument panel
decorative strip (2).
2007 BMW 335i
Fig. 225: Identifying Hazard Warning Flashers/Central Locking Switch And Right Instrument Panel
Decorative Strip
61 31 083 REMOVING AND INSTALLING/REPLACING SWITCH FOR UNLOCKING REAR LID
NOTE: To facilitate handling, unclip OBD socket cover (1).
Unclip switch for unlocking rear lid (2) towards rear.
Disconnect associated plug connection and remove switch for unlocking rear lid (2).
Fig. 226: Identifying Rear Lid Switch, OBD Socket Cover And Removal Direction
61 31 100 REMOVING AND INSTALLING/REPLACING SWITCH FOR LONGITUDINAL SEAT

ADJUSTMENT
Raise release unit (1).
Unclip release unit trim (2) in direction of arrow and feed out of release unit (1).
2007 BMW 335i
Installation:
First feed release unit trim (2) at front into release unit (1), then clip into place in rear area.
Make sure release unit trim (2) is correctly engaged and seated on release unit (1).
Fig. 227: Releasing Unit Trim

Unlock retaining tabs (2) in direction of arrow.
Remove switch for longitudinal seat adjustment (3) in direction of arrow.
Installation:
Switch for longitudinal seat adjustment (3) must snap audibly onto release unit trim.
Fig. 228: Disconnecting Plug Connection

61 31 101 REMOVING AND INSTALLING/REPLACING SWITCH FOR BACKREST WIDTH

ADJUSTMENT
2007 BMW 335i
 Remove Outer Cover on front seat
Unlock retaining tab (2) in direction of arrow.
Remove switch for backrest width adjustment (3) in direction of arrow.
Fig. 229: Identifying Plug Connection, Retaining Tab, Backrest Width Adjustment Switch And Removal
Direction
61 31 101 REMOVING AND INSTALLING/REPLACING SWITCH FOR LONGITUDINAL SEAT

ADJUSTMENT
Raise release unit (1).
Unclip release trim (2) in direction of arrow and feed out of release unit (2).
Fig. 230: Identifying Trim, Unit And Removal Direction

2007 BMW 335i
Unlock retaining tab (2) in direction of arrow.
Remove switch for backrest width adjustment (3) in direction of arrow.
Fig. 231: Identifying Plug Connection, Retaining Tab, Backrest Width Adjustment Switch And Removal
Direction
61 31 113 REMOVING AND INSTALLING/REPLACING BOTH SHIFT PADDLES FOR

AUTOMATIC TRANSMISSION
 Remove Airbag Unit
Release screws (2).
Remove shift paddles for automatic transmission (3) in direction of travel.
Installation:
Make sure electrical leads are correctly routed.
Make sure shift paddles for automatic transmission are correctly seated on steering wheel.
2007 BMW 335i
Fig. 232: Identifying Plug Connection, Shift Paddles And Screw

61 31 115 REPLACING ROCKER SWITCH FOR SIDE WINDOW OPERATION (SWITCH

CLUSTER, FRONT)
 00 9 340
IMPORTANT: Carry out the following work step carefully in order to avoid damaging door
trim panel and rocker switch.
Carefully lever out rocker switch for side window operation (1) with special tool 00 9 340 at specified points
(2).
Remove rocker switch for side window operation (1) from door trim panel (3) slightly.
Disconnect associated plug connection and remove rocker switch for side window operation (1).
Fig. 233: Identifying Special Tool (00 9 341), Side Window Operation Switch, Specified Points, And Trim
Panel
2007 BMW 335i
Installation:
Retaining clips (1) of rocker switch for side window operation (2) must not be damaged or missing.
Make sure rocker switch for side window operation (2) is correctly seated.
Fig. 234: Identifying Clips And Side Window Operation Switch

61 31 115 REPLACING ROCKER SWITCH FOR SIDE WINDOW OPERATION (FRONT)
IMPORTANT: Carry out the following operations carefully so as to avoid damaging the door
trim panel and rocker switch.
If necessary, tape off working area.
Driver's side:
Lever rocker switch for side window operation (1) with special tool 00 9 341 at highlighted points (2) out of
armrest (3).
2007 BMW 335i
Fig. 235: Removing Rocker Switch For Side Window Operation

Installation:
Retaining clips (1) of rocker switch for side window operation (2) must not be damaged or missing.
Make sure rocker switch for side window operation (2) is correctly seated in armrest.
Fig. 236: Identifying Retaining Clips And Side Window Operation

Passenger side:
Lever rocker switch for side window operation (1) with special tool 00 9 317 in direction of arrow out of
armrest.
2007 BMW 335i
Fig. 237: Removing Rocker Switch For Side Window Operation

Installation:
Retaining hooks (1) of rocker switch for side window operation (2) must not be damaged.
Make sure rocker switch for side window operation (2) is correctly seated in armrest.
Fig. 238: Identifying Retaining Hooks And Side Window Operation

61 31 122 REMOVING AND INSTALLING / REPLACING TOW HITCH SWITCH
 Open Flap In Luggage Compartment Panel on right
Release cable strap with holders (1).
Fold luggage compartment cover on side panel (2) in direction of arrow.

2007 BMW 335i
Fig. 239: Identifying Cable Strap With Holders And Side Panel
Release screw (1).
Disconnect plug connection underneath and remove tow hitch switch (2).
Fig. 240: Identifying Tow Hitch Switch And Screw

61 31 133 REMOVING AND INSTALLING/REPLACING AV CONNECTION SOCKET
 00 9 317

 Remove Rear Console Trim At Front
 Remove Rear Console At Rear
2007 BMW 335i
Slide special tool 00 9 317 under storage compartment (1) and press AV connection socket (2) upwards out of
storage compartment (1).
Fig. 241: Identifying Special Tool (00 7 317), Storage Compartment And AV Connection Socket
Remove AV connection socket (2) upwards out of storage compartment (3).
Installation:
Locks (4) must not be damaged.
Make AV connection socket (1) is correctly seated in storage compartment (3).
Fig. 242: Identifying Storage Compartment, Locks, AV Connection Socket And Plug Connection
61 31 134 REMOVING AND INSTALLING/REPLACING USB AUDIO INTERFACE CONNECTING

SOCKET

2007 BMW 335i
Removing and installing/replacing AV connecting socket
61 31 192 REPLACING KNOB FOR CONTROLLER
 00 9 317
Partially fit special tool 00 9 317 as illustrated.
Lever out knob for controller (1) from controller (2) and remove towards top.
Fig. 243: Identifying Special Tool (00 9 317), Controller Knob, Controller And Removal Direction
Install knob for controller only when controller is installed.
Installation:
Fit knob for controller (1) so that guides (2) are correctly seated in mountings (3).
2007 BMW 335i
Fig. 244: Identifying Controller Knob, Guides And Mountings

61 31 195 REMOVING AND INSTALLING (REPLACING) FRONT CONTROLLER

 Replacement only: Remove Knob For Controller
Install knob for controller only when controller is installed.
Release screws (1).
Feed controller (2) in direction of arrow out of trim (3) and remove.
Fig. 245: Identifying Screws, Controller, Trim And Removal Direction

Replacement:
2007 BMW 335i
Carry out Vehicle Programming/Coding
61 31 204 REPLACING SWITCH COMBINATION FOR SEAT ADJUSTMENT
Unlock retaining tabs (3) in direction of arrow and remove switch combination (1) from cover.
Installation:
Retaining tabs (3) of cover and guide (4) of switch combination (1) must not be damaged.
Make sure switch combination (1) is correctly seated in retaining tabs (3).
Fig. 246: Identifying Plug Connection, Switch Combination, Retaining Tabs, Guide And Removal
Direction
61 31 208 REMOVING AND INSTALLING/REPLACING SWITCH FOR LUMBAR SUPPORT
Unlock catches (1).
Remove switch for lumbar support (2) in direction of arrow.

2007 BMW 335i
Fig. 247: Identifying Lumbar Support, Plug Connection, Catches And Removal Direction
61 31 221 REMOVING AND INSTALLING/REPLACING BOTH MULTIFUNCTION STEERING

WHEEL SWITCHES

NOTE: Both multifunction steering wheel switches (1) are connected to each other by
the wiring harness.
Pull multifunction steering wheel switches (1) in direction of arrow out of steering wheel.
Feed wiring harness out of steering wheel and remove both multifunction steering wheel switches.
Installation:

2007 BMW 335i
Fig. 248: Identifying Multifunction Steering Wheel Switches And Plug Connection
Installation:
Guides (2) of multifunction steering wheel switches (1) must be correctly seated in corresponding locators (3)
on steering wheel.
Fig. 249: Identifying Guides And Multifunction Steering Wheel Switches

61 31 229 REMOVING AND INSTALLING/REPLACING BOTH SWITCHES ON SPORT STEERING

WHEEL
NOTE: Illustrations show multifunction steering wheel (4) removed.
Release screws (1).

2007 BMW 335i
Detach decorative trim (3) in direction of arrow from holders (2).
Disconnect associated plug connection and remove complete decorative trim (3).
Installation:
Fig. 250: Identifying Decorative Trim, Holders, Screws, Steering Wheel And Removal Direction
Feed wiring harness (4) out of associated holders.
Release screws (1) and remove both multifunction steering wheel switches (2) from decorative trim (3).
Installation:
Make sure there is a uniform gap between both multifunction steering wheel switches (2) and decorative trim
(3).
Fig. 251: Identifying Multifunction Steering Wheel Switches, Wiring Harness, Screws And Decorative
Trim
2007 BMW 335i
61 31 235 REPLACING MICROSWITCH ON LEFT OR RIGHT FRONT SEAT (CONVERTIBLE)
Remove carrier of outer cover on front seat .
If necessary, partially detach seat cover .
Remove plug connection (1) from microswitch cover (2) and disconnect.
Unclip microswitch cover (2) and remove in direction of arrow.
Installation:
Make sure microswitch cover is correctly seated.
Fig. 252: Identifying Microswitch Cover And Connector

Remove screw (1) completely by pulling gently.
NOTE: Screw (1) goes through two thread turns.
Raise locking pawl (2) slightly by pulling release handle and remove microswitch (3) in direction of arrow.
2007 BMW 335i
Fig. 253: Removing Microswitch

Installation:
Make sure bushing (1) and guides (2) are correctly seated.
Tightening torque: see 11AZ in 52 10 front seats .
Fig. 254: Identifying Bushing And Guides

Installation:
Before fitting microswitch cover (4), carry out function test of microswitch (3) with backrest folded back:
 Insert microswitch plug connection.

 Switch ignition on.
 Locking pawl (1) is at bottom, microswitch (3) is actuated, belt warning lamp must not light up/flash.
 Raise locking pawl (1) with release handle, microswitch (3) is not actuated, belt warning lamp must flash.
2007 BMW 335i
 If necessary, replace microswitch (3).
IMPORTANT: Do not bend switching spring (2) on microswitch (3).
Fig. 255: Identifying Microswitch, Switching Spring, Locking Pawl, And Microswitch Cover
61 31 241 REMOVING AND INSTALLING/REPLACING ENGINE HOOD CONTACT SWITCH
Press catches (2) together and feed hood contact switch (3) in direction of arrow out of fixture (4).
Fig. 256: Identifying Catches, Plug Connection, Hood Contact Switch, Fixture And Removal Direction
61 31 255 REPLACING SWITCH FOR DOOR MIRROR
Replacing Rocker Switch For Side Window Operation

2007 BMW 335i
61 31 270 REPLACING SWITCH FOR REVERSING LIGHT
NOTE: The installation location of the reversing light switch can vary, depending on
the transmission model.
 If necessary, remove REAR UNDERBODY PROTECTION .
Version A:
Release switch for reversing light (2).
Fig. 257: Identifying Plug Connection And Switch For Reversing Light (Version A)
Version B:
Release switch for reversing light (2).

2007 BMW 335i
Fig. 258: Identifying Plug Connection And Switch For Reversing Light (Version B)
61 31 299 REMOVING AND INSTALLING/REPLACING CLUTCH SWITCH MODULE
NOTE: Clutch master cylinder (2) is removed for purposes of clarity.
Lever out clutch switch module (1) from clutch master cylinder (2) with screwdriver.
Unlock plug (4) and disconnect from housing (3).
Fig. 259: Identifying Clutch Switch Module, Plug, Housing, Clutch Master Cylinder And Removal
Direction
Installation:
2007 BMW 335i
Clutch switch module is secured against incorrect installation.
Clutch switch module must snap audibly in to place.
Fig. 260: Identifying Clutch Switch Module

61 31 310 REPLACING BRAKE LIGHT SWITCH
Pull brake light switch (2) in direction of arrow out of brake light switch holder (3).
Installation:
 Press brake pedal (4) to floor.

 Slide brake light switch (2) as far as it will go into brake light switch holder (3).
 Grip brake light switch holder (3), slowly return brake pedal (4) to starting position and pull back to stop.
2007 BMW 335i
Fig. 261: Identifying Plug Connection, Brake Light Switch, Holder, Brake Pedal And Removal
Direction
NOTE: Removing brake light switch holder (2):

Press brake pedal.
Press catches (1) together and unclip brake light switch holder (2) from
bearing block (3).
Fig. 262: Identifying Brake Light Switch Holder, Bearing Block, Catches And Removal Direction
61 31 382 REPLACING COOLANT LEVEL SWITCH
IMPORTANT: Do not damage connected water hoses.
If necessary, catch escaping coolant and feed back in later.
If necessary, remove coolant expansion tank (2).
Release bolts (1).
Pull coolant expansion tank (2) in direction of arrow out of grommet (3) underneath and raise slightly.
Disconnect plug connection from coolant level switch (4).
Installation:
 Make sure coolant expansion tank (2) is correctly seated in grommet (3)
 If necessary, replace grommet (3)
2007 BMW 335i
Fig. 263: Identifying Grommet, Bolts, Coolant Level Switch, Coolant Expansion Tank And
Removal Direction
NOTE: For purposes of clarity, illustration shows coolant expansion tank (2)
removed.
Turn coolant level switch (1) in direction of arrow, pull upwards out of coolant expansion tank (2) and
remove.
Fig. 264: Identifying Coolant Level Switch, Coolant Expansion Tank And Removal Direction
61 31 492 REPLACING LEVEL SWITCH FOR WINDSCREEN WASHER SYSTEM
 Release Fluid Reservoir For Windscreen Washer System and pull out
Turn level switch for windscreen washer system (2) in direction of arrow and remove towards bottom from
2007 BMW 335i
fluid reservoir for windscreen washer system (3).
Fig. 265: Identifying Level Switch, Fluid Reservoir, Plug Connection And Removal Direction
61 31 996 CARRY OUT STEERING ANGLE SENSOR ADJUSTMENT
IMPORTANT: In vehicles with active front steering, steering angle sensor adjustment is
integrated in the service function "Initial operation/adjustment for active front
steering" and must not be carried out separately!
NOTE: Steering angle sensor adjustment must be carried out:
 after adjustment work on the front axle/steering

 after all mechanical work on the steering system
 after replacement / coding / programming of the following components:
 Fixture for switches of steering column / switch cluster / steering
angle sensor
 Dynamic Stability Control (DSC) control unit
 Control unit active anti-roll stabilization (ARS)
Connect vehicle to BMW diagnosis system or Software Service Station.
Select and carry out steering angle sensor adjustment under Service functions.
HORN
61 33 050 REMOVING AND INSTALLING/REPLACING LEFT FANFARE HORN
 Remove Front Wheel Arch Cover (front section)

2007 BMW 335i
Release nut (1) and remove fanfare horn (2) from bracket (3).
Unlock associated plug connection and disconnect.
Remove fanfare horn (2).
Fig. 266: Identifying Nut, Fanfare Horn And Bracket

61 33 055 REMOVING AND INSTALLING/REPLACING RIGHT FANFARE HORN
 Remove front right Wheel Arch Cover (front section)
N54:
 Remove front bumper trim
Release nut (1) and remove fanfare horn (2) from bracket (3).
Remove fanfare horn (2).

2007 BMW 335i
Fig. 267: Identifying Nut, Fanfare Horn And Bracket

INSERT HOLDER FOR CIGARETTE LIGHTER

61 34... REMOVING AND INSTALLING OR REPLACING SOCKET OUTLET IN LUGGAGE
COMPARTMENT
NOTE: Work is shown on the E82 by way of example. There may be differences in
Expose guides (1) of cover (2).
Remove cover (2) in direction of arrow from luggage compartment wheel arch trim (3).
Press socket frame (4) from rear out of luggage compartment wheel arch trim (3).
Disconnect plug connection behind.
Installation:
Retaining lugs (5) and luggage compartment wheel arch trim (3) must not be damaged.
Make sure socket frame (4) is correctly seated on luggage compartment wheel arch trim (3).
2007 BMW 335i
Fig. 268: Disconnecting Plug Connection

Unlock catches (1) with a suitable tool and feed socket receptacle (2) in direction of arrow out of socket frame
(3).
Installation:
Catches (1) on socket receptacle (2) must not be damaged.
Make sure socket receptacle (2) is correctly seated in socket frame (3).
Fig. 269: Identifying Socket Frame & Catches

Unlock catches (1) with a suitable tool and feed socket (2) in direction of arrow out of socket receptacle (3).
Installation:
Catches (1) on socket receptacle (3) must not be damaged.
Ensure catches (1) are correctly seated.

2007 BMW 335i
Fig. 270: Identifying Catches With SST

CONTROL UNITS, MODULES

61 35.. OVERVIEW OF CONTROL UNITS (COUPE)
Fig. 271: Overview Of Control Units (Coupe)

2007 BMW 335i
61 35.. OVERVIEW OF CONTROL UNITS (CONVERTIBLE)
Fig. 272: Overview Of Control Units (Convertible)

84 10 050 REMOVING AND INSTALLING (REPLACING) USB HUB
PROTECTION).
 Remove LEFT FRONT SEAT

 Remove FRONT LEFT ENTRANCE COVER STRIP
 Fold back carpet for passenger compartment at front left in direction of travel
Remove USB hub protective socket (1) from footwell insert (2).
Unlock catches (3) with a suitable tool and remove USB hub protective socket cover (5).
Installation:
Make sure USB hub protective socket cover (5) engages correctly on USB hub protective socket lower section.
2007 BMW 335i
Seal (4) must not be damaged; if necessary, replace USB hub protective socket cover (5).
Fig. 273: Identifying USB Hub Protective Socket With Cover, Socket And Seal
Remove USB hub (1) from USB hub protective socket lower section (2).
Installation:
Make sure rubber grommet (4) is correctly seated on USB hub protective socket lower section (2).
Fig. 274: Identifying USB Hub With Protective Socket Lower Section, Plug Connection And Rubber
Grommet
61 35... NOTES ON ESD PROTECTION (ELECTRO STATIC DISCHARGE)
 12 7 060
2007 BMW 335i
NOTE: Electrical components which are particularly sensitive to electrostatic

discharge (electronic control units, sensors, etc.) are marked with the ESD
warning symbol.
E -Electro
S -Static
D -Discharge
Statically charged persons can discharge by touching electrical components.
NOTE: Humans can only detect a discharge starting from a level of approx. 3000 V.
The danger threshold for electrical components already starts from a level of
approx. 100 V.
Fig. 275: Precaution For Touching Electrical Components

Example:
Mechatronic control unit.

2007 BMW 335i
Fig. 276: Mechatronic Control Unit

Fig. 277: Precaution For Handling Mechatronic Control Unit

IMPORTANT: Do not touch pins or multi-pin connectors directly!
Touch electrical components by their housings only.
IMPORTANT: To prevent electrical components from being damaged or destroyed by

2007 BMW 335i
electrostatic discharge, it is absolutely essential to comply with the following

instructions:
 When replacing electrical components, leave the replacement

components in their original packaging until immediately before they are
to be installed
 If necessary, always return a removed component in its original
packaging (always pack the component away immediately)
 Read and comply with user information on using the associated special
tool 12 7 060
61 35 001 REMOVING AND INSTALLING TRAILER MODULE (COUPE)
Protection)!.

 Remove right Luggage Compartment Trim Panel
 Partially detach insulating mat
Release screws (1) and pull back device holder (2).
Fig. 278: Identifying Screws, Device Holder And Removal Direction

Unlock catch (2) in direction of arrow and remove trailer module (3) upwards from device carrier (4).
2007 BMW 335i
Fig. 279: Identifying Catch, Trailer Module, Device Carrier, Plug Connection And Removal Direction
Replacement:
61 35 001 REMOVING AND INSTALLING TRAILER MODULE (CONVERTIBLE)
Protection)!.
Fig. 280: Identifying Connector

2007 BMW 335i
Unlock catch (1) and remove trailer module (2) from device carrier (3).
Fig. 281: Identifying Device Carrier, Trailer Module, And Catch

61 35 015 REMOVING AND INSTALLING (REPLACING) CONTROL UNIT FOR CAR ACCESS
SYSTEM
Protection)!
NOTE: The comfort access system is a radio-based system and can be interfered with
by radio waves from other systems (e.g. mobile phone).
 Remove Decorative Strip On Instrument Panel On Left

 Remove Light Operator Unit
IMPORTANT: Carefully unlock and disconnect associated plug connection for ribbon cable
(1).
Replace ribbon cable (1) if damaged.
The ribbon cable leads to:
 Insert For Radio Control Key

 Start/Stop Switch
2007 BMW 335i
Release screw (3) and remove control unit for Car Access System (4) in downward direction.
Fig. 282: Identifying Screw, Plug Connection, Ribbon Cable And Control Unit
Installation:
Feed guide (1) of control unit for Car Access System (2) correctly into associated mounting.
Fig. 283: Identifying Guide And Control Unit

Replacement:
Version with independent heating:
Initialize Telestart hand transmitter.
61 35 080 REMOVING AND INSTALLING (REPLACING) CONTROL UNIT FOR LEFT OR RIGHT
SEAT ADJUSTMENT (FRONT SEAT) (COUPE)
2007 BMW 335i
Protection)!
NOTE: To facilitate installation/removal of control unit, move seat upwards fully.
Unlock metal lug (1) towards front and remove control unit for seat adjustment (2) towards bottom.
Unlock and disconnect all associated plug connections.
Fig. 284: Identifying Metal Lug, Control Unit And Removal Direction
Installation:
Make sure control unit for seat adjustment (1) is correctly seated in mounting (2).
Guides (3) and metal lug (4) must not be damaged.
Fig. 285: Identifying Mounting, Guides, Control Unit And Metal Lug
Replacement:
2007 BMW 335i
61 35 080 REMOVING AND INSTALLING (REPLACING) CONTROL UNIT FOR LEFT OR RIGHT
SEAT ADJUSTMENT (FRONT SEAT) (CONVERTIBLE)
Damage (ESD Protection)!!
 Remove front seat
Disconnect all plug connections (1).
Lever out control unit (2) in direction of arrow with special tool 00 9 317 and remove.
Installation:
Make sure control unit for seat adjustment (2) is correctly seated in mounting (3).
Fig. 286: Removing Control Unit/Module For Left Or Right Seat Adjustment
Replacement:
Carry out Vehicle Programming/Coding.
84 21 542 REMOVING AND INSTALLING (REPLACING) HANDSFREE CHARGING

ELECTRONICS (HIGH)
PROTECTION).
2007 BMW 335i
NOTE: Comply with notes and instructions on HANDLING OPTICAL WAVEGUIDES.

 Remove LUGGAGE COMPARTMENT FLOOR TRIM
E91:
Release retaining clips (1) and remove storage pan (2).
Fold panel (3) upwards.
Fig. 287: Identifying Retaining Clips, Panel And Storage Pan

Unscrew nuts (1).
Remove holder for telematics control unit/SES (2) in direction of arrow from body.
E88/E93:
Raise panel for luggage compartment partition (4) slightly and feed out holder for telematics control unit/SES
(2) in direction of luggage compartment.
Release wiring harness fastener (3) from holder for telematics control unit/SES (2).
2007 BMW 335i
Fig. 288: Removing Holder For Telematics Control Unit / SES

Installation:
Make sure guides (5) are correctly seated in associated body holders.
Make sure wiring harness is correctly laid.
Release all nuts.
Remove hands-free charging electronics (3) from holder for telematics control unit/SES (2).
Fig. 289: Locating Hands-Free Charging Electronics Nuts

Replacement:
 Carry out VEHICLE PROGRAMMING/CODING

 If necessary, log mobile phone on to vehicle
61 35 095 REMOVING AND INSTALLING/REPLACING CONTROL UNIT/MODULE FOR SEAT

2007 BMW 335i
HEATING
Protection)!
NOTE: Move seat completely towards rear/top.
Open lock (2) in direction of arrow and remove control unit/module for seat heating (3) towards bottom.
Installation:
Make sure control unit/module for seat heating (3) is correctly engaged.
Fig. 290: Identifying Plug Connection, Control Unit/Module, Lock And Removal Direction
61 35 107 REMOVING AND INSTALLING/REPLACING JUNCTION BOX ELECTRONICS
Protection)!

 Remove Footwell Side Trim Panel on A-pillar, right
 Remove Trim For Instrument Panel , bottom right
NOTE: Right glovebox shown removed for purposes of clarity.

2007 BMW 335i
Release screws (2) and remove junction box electronics (3) from bracket.
Fig. 291: Identifying Screws, Plug Connections And Junction Box Electronics
Installation:
Make sure junction box electronics is correctly seated in plug connection (2) of bracket.
Fig. 292: Identifying Plug Connections And Junction Box

Replacement:

 Delete transport mode
61 35 115 REMOVING AND INSTALLING/REPLACING FOOTWELL MODULE
2007 BMW 335i
Protection)!
 Remove Footwell Side Trim Panel On A-Pillar, Left
Release plastic nuts (2) and remove footwell module (3).
Fig. 293: Identifying Plastic Nuts, Plug Connections And Footwell Module
Replacement:
61 35 177 REMOVING AND INSTALLING (REPLACING) RAIN/LIGHT SENSOR
Protection)!
Version with Autobeam:
 Remove Interior Rear-View Mirror
Expand two-part mirror base cover (1) by pressing from below and detach.
Feed out two-part mirror base cover (1) and remove.
NOTE: Catches of two-part mirror base cover (1) must not be damaged.
2007 BMW 335i
Fig. 294: Identifying Two-Part Mirror Base Cover And Removal Direction
Press locks (1) in direction of arrow and remove rain/light sensor (2) towards bottom.
Installation:
Do not damage optical element covered by rain/light sensor (2).
If necessary, initialize Rain/Light Sensor.
Fig. 295: Identifying Plug Connections, Locks, Rain/Light Sensor And Removal Direction
Replacement:
61 35 201 REMOVING AND INSTALLING/REPLACING LCPA MODULE

2007 BMW 335i

 Remove Armrest Side Section On Rear Seat Backrest
Unlock catch (2) and remove LCPA module (3) in direction of arrow.
Fig. 296: Identifying Catch, LCPA Module, Plug Connection And Removal Direction
Installation:
Feed guide (1) of LCPA module (2) correctly into locator (3).
Fig. 297: Identifying Guide, Locator And LCPA Module

61 35 679 INITIALIZING RAIN/LIGHT (SOLAR) SENSOR

2007 BMW 335i
NOTE: Initialization is necessary:
 after replacing windscreen

 after replacing rain/light (solar) sensor
 after replacing optical element on rain/light (solar) sensor
 after installing a used rain/light (solar) sensor
NOTE:  Connect BMW diagnosis system

 Initialize rain/light (solar) sensor.
61 35 950 REMOVING AND INSTALLING (REPLACING) CONTROL UNIT FOR COMFORT

ACCESS SYSTEM (COUPE)
Protection)!

 Partially detach insulating mat
Release screws (1) and pull back device holder (2).
Fig. 298: Identifying Screws, Device Holder And Removal Direction

Unlock catch (2) in direction of arrow and remove control unit for comfort access system (3) upwards from
device carrier (4).
2007 BMW 335i
Fig. 299: Identifying Catch, Control Unit And Device Carrier

Replacement:
61 35 950 REMOVING AND INSTALLING (REPLACING) CONTROL UNIT FOR COMFORT

ACCESS SYSTEM (CONVERTIBLE)
Protection).
Removing and installing/replacing right luggage compartment wheel arch trim
Partially detach insulating mat (1).
Release nuts (4) and remove control unit (3).

2007 BMW 335i
Fig. 300: Removing Control Unit For Comfort Access System (Convertible)
Replacement:
Carry out programming/coding
61 35 953 REMOVING AND INSTALLING/REPLACING INTERIOR ANTENNA FOR COMFORT

ACCESS SYSTEM (FRONT)

 Remove Trim For Storage Tray
Remove interior aerial for comfort access system (2) in direction of arrow.
2007 BMW 335i
Fig. 301: Identifying Plug Connection, Interior Aerial And Removal Direction
61 35 954 REMOVING AND INSTALLING/REPLACING INTERIOR ANTENNA FOR COMFORT

ACCESS SYSTEM (REAR)

Remove interior antenna for comfort access system (2) in direction of arrow.
Fig. 302: Identifying Plug Connection, Interior Antenna And Removal Direction
61 35 970 REMOVING AND INSTALLING/REPLACING REAR LUGGAGE COMPARTMENT

ANTENNA FOR COMFORT ACCESS SYSTEM (COUPE)
2007 BMW 335i
 Remove Luggage Compartment Floor Trim Panel.
Unlock catches (2) and remove luggage compartment antenna for comfort access system (3) in direction of
arrow from holder (4).
Fig. 303: Identifying Plug Connection, Catches, Luggage Compartment Antenna, Holder And Removal
Direction
61 35 970 REMOVING AND INSTALLING/REPLACING REAR LUGGAGE COMPARTMENT

ANTENNA FOR COMFORT ACCESS SYSTEM (CONVERTIBLE)
 Remove Luggage Compartment Floor Trim Panel.
Unlock catch (2) and remove luggage compartment antenna for comfort access system (3).
2007 BMW 335i
Fig. 304: Removing Rear Luggage Compartment Antenna For Comfort Access System (Convertible)
61 35 975 REMOVING AND INSTALLING/REPLACING BUMPER ANTENNA FOR COMFORT

ACCESS SYSTEM
 Remove Rear Bumper Trim
Press catches (1), feed out bumper antenna for comfort access system (3) in direction of arrow and remove.
Fig. 305: Identifying Plug Connection, Catches, Bumper Antenna And Removal Direction
32 43 010 REMOVING AND INSTALLING/REPLACING CONTROL UNIT FOR ACTIVE FRONT

STEERING

2007 BMW 335i
DAMAGE (ESD PROTECTION).

 Remove FRONT LEFT WHEEL ARCH COVER (REAR SECTION)
Release screw (1) and remove grounding cable.
Unlock plug (2) with a suitable tool and detach.
Open cable tie (arrowed).
Installation:
Replace faulty cable holder (4).
Fig. 306: Identifying Cable Holder, Plug And Screw

Unscrew nut (1).
Release screw (2).
Remove active front steering control unit (3).

2007 BMW 335i
Fig. 307: Identifying Active Front Steering Control Unit With Screw And Nut
After installation
 Replacement only: Carry out PROGRAMMING/CODING

 Carry out ADJUSTMENT FOR ACTIVE FRONT STEERING
61 35 146 REMOVING AND INSTALLING/REPLACING CONVERTIBLE TOP MODULE

DAMAGE (ESD PROTECTION).
Fig. 308: Identifying Connector

2007 BMW 335i
Fold back insulating mat (3).
Unlock catch (2) and remove convertible top module (4) from device carrier.
Fig. 309: Identifying Insulating Mat, Catch, And Expansion Rivets

Replacement:
64 11 970 REPLACING FOGGING SENSOR
Notes
WARNING: Make sure rooms are well ventilated when working with adhesive remover
indoors.
IMPORTANT: Do not under any circumstances use paint thinner to clean the bonding
surface.
Expand two-part mirror base cover (1) by pressing from below and detach.
Feed out two-part mirror base cover (1) and remove.

2007 BMW 335i
Fig. 310: Removing Two-Part Mirror Base Cover

NOTE: If necessary, carefully heat fogging sensor (2) with a hot air blower to approx.
40-60°C.
Lift off fogging sensor (2) with special tool 00 9 317 and slowly pull off from windshield.
Installation:
Bonding surface must be dry and free of dust and grease.
Fig. 311: Lifting Off Fogging Sensor Using Special Tool (00 9 317)
Clean bonding surface with adhesive remover (sourcing reference: BMW Parts Service).
After cleaning, do not touch bonding surface with bare hands.

2007 BMW 335i
Pull off protective film completely from fogging sensor (3).
Place mounting template (1) as pictured on rain sensor (2).
Press fogging sensor (3) in direction of arrow with a contact pressure of > or = 15 N/cm 2 onto inside of
windshield.
NOTE: Firm thumb pressure attains approx. 30 N/cm2 .
Fig. 312: Pressing Fogging Sensor

Remove mounting template (1) carefully from fogging sensor (3).
61 00... VEHICLE PROGRAMMING AND CODING
Select menu item (1).
Select corresponding procedure from selection list.
Example:
 Preparation and subsequent evaluation of vehicle programming

 Start a Progman session
 Sequence of BMW/MINI vehicle programming and coding
 BMW/MINI Car & Key Memory
 BMW/MINI initialization
 BMW/MINI service function s in Progman
2007 BMW 335i
Fig. 313: Diagnosis Function Screen Display

NOTE: In order to avoid incorrect programming procedures and error messages, it is

essential when working with the Progman programming system always to use
the latest Progman version.
WINDSCREEN WIPERS
61 61.. OVERVIEW OF WINDSCREEN WIPER AND WASHER SYSTEM
2007 BMW 335i
Fig. 314: Overview Of Windscreen Wiper And Washer System

61 61 01 ADJUSTING LEFT OR RIGHT WINDSCREEN WIPER
 61 6 100
Correctly adjusting the contact angle of the wiper arms on the windscreen increases wiping quality. For
adjustment, refer to the vehicle-specific repair instruction.
2007 BMW 335i
Fig. 315: Identifying Contact Angle Of Wiper Arms On Windscreen

A/B = Distance between windscreen wiper blade (2) and trim panel on cowl panel (1)
NOTE: Measurement is taken at the height of the locators (3) for the windscreen wiper
arms
C= Contact angle between wiper blade center plane and windscreen
When adjusting with special tool 61 6 100 , set the scale value in accordance with the following table.
For RHD cars, change the preceding sign of the scale values.
 LHD cars, scale range 0 to -10

 RHD cars, scale range 0 to +10
SCALE RANGE CHART

Contact angle (C) on Scale value (LHD) on Adjustment dimension (A, B) on
windscreen wiper arm special tool windscreen wiper arm
Model
Passenger Driver
Passenger side Driver side Passenger side Driver side Rear end
side side
85.5° +1.5 to 85.5° +1.5 to
2007 BMW 335i
E81 1.0° 1.0° -5 -5 47 ± 3 mm 54 ± 3 mm

85.5° +1.5 to 85.5° +1.5 to
E82 -5 -5 47 ± 3 mm 54 ± 3 mm
1' 1.0° 1.0°
85.5° +1.5 to 85.5° +1.5 to
E87 -5 -5 47 ± 3 mm 54 ± 3 mm
1.0° 1.0°
E46 85.7° ± 1° 85.3° ± 1° -4 -5
E83 85.2° ± 1° 85.4° ± 1° -5 -5 66 ± 3 mm 61 ± 3 mm 29 ± 1 mm
E90 86.7° ± 1° 86.0° ± 1° -3 -4 88 ± 3 mm 95 ± 3 mm
3'
E91 86.7° ± 1° 86.0° ± 1° -3 -4 88 ± 3 mm 95 ± 3 mm 35 ± 3 mm
E92 86.7° ± 1° 86.0° ± 1° -3 -4 75 ± 3 mm 84 ± 3 mm
E93 86.7° ± 1° 86.0° ± 1° -3 -4 75 ± 3 mm 84 ± 3 mm
60.1 ±1
E39 86.5° ± 1° 86.5° ± 1° -4 -4
mm
32.5 ± 2
E53 85.0° ± 1° 85.0° ± 1° -5 -5 54 ± 3 mm 55 ± 3 mm
5' mm
E60 86.0° ±1° 86.0° ±1° -4 -4 69 ± 3 mm 87 ± 3 mm
E61 86.0° ±1° 86.0° ±1° -4 -4 69 ± 3 mm 87 ± 3 mm 30 ± 3 mm
E70 85.6° ±1° 85.0° ± 1° -4 -5 103 ±3 mm 90 ±3 mm 39 ±2 mm
E63 86.0° ±1° 86.0° ±1° -4 -4 69 ± 3 mm 87 ± 3 mm
6'
E64 86.0° ±1° 86.0° ±1° -4 -4 69 ± 3 mm 87 ± 3 mm
E38 87.0° ±1° 87.0° ±1° -3 -3 65 ± 3 mm 58 ± 3 mm
7' E65 85.5° ±1° 87.0° ±1° - - 20 ± 3 mm 48 ± 3 mm
E66 85.5° ±1° 87.0° ±1° - - 20 ± 3 mm 48 ± 3 mm
104 ± 2
8' E52 85.5° ±1° 85.5° ±1° -4 -4 38 ± 2 mm
mm
E85 85.5° ±1° 85.5° ±1° -4 -4 57 ± 2 mm 52 ± 2 mm
Z
E86 85.5° ±1° 85.5° ±1° -4 -4 57 ± 2 mm 52 ± 2 mm
61 61 010 CHECKING/ADJUSTING CONTACT ANGLE OF WINDSCREEN WIPER ARMS ON

WINDSCREEN
Notes
NOTE: Wiping quality is increased if the approach angle of the windscreen wiper arms
is precisely adjusted.
Adjusting DIMENSIONS of wiper arms:
Reference points (A, B) are the mountings of the wiper blades on the wiper arms to the sealing lip (1) of the
cowl panel.
Contact angle (C) is the angle between wiper blade center plane (2) and windscreen.
2007 BMW 335i
Fig. 316: Identifying Dimensions Of Wiper Arms

Remove wiper blade (1) from wiper arm (2).
Pin (3) is locator for special tool 61 6 100 .
Fig. 317: Identifying Wiper Blade, Wiper Arm And Pin Of Special Tool (61 6 100)
Slide special tool 61 6 100 onto pin (1).
Place special tool 61 6 100 on windscreen (2) and read off value in degrees on scale.
NOTE: LHD vehicles are covered by the scale range of 0 to -10 and RHD vehicles by the
scale range of 0 to +10.
2007 BMW 335i
Fig. 318: Sliding Special Tool (61 6 100) Onto Pin

If the specified number in degrees is not correct, the wiper arm (1) must be bent with the special tool 61 6 110 at
the point shown.
Fig. 319: Bending Wiper Arm Using Special Tool (61 6 110)
61 61 041 REPLACING BOTH WINDSCREEN WIPER BLADES
IMPORTANT: Make sure the wiper arm does not contact the windscreen without its wiper
blade.
Fold wiper arm (3) away from windscreen.
Press lock (1) and remove cover cap (2) in direction of arrow.
Installation:
2007 BMW 335i
Make sure cover cap (2) is correctly seated.
Fig. 320: Identifying Wiper Arm, Cover Cap, Lock And Removal Direction
Turn windscreen wiper blade (1) at an angle of 90° and remove from windscreen wiper arm (2).
Fig. 321: Identifying Windscreen Wiper Blade, Windscreen Wiper Arm And Removal Direction
Installation:
Catches (1) and guide (2) of window cavity cover cap (6) must not be damaged or missing.
2007 BMW 335i
Fig. 322: Identifying Catches, Guide And Window Cavity Cover Cap
61 61 100 REMOVING AND INSTALLING/REPLACING BOTH WINDSCREEN WIPER ARMS
 61 6 210
Take off cap.
Fig. 323: Identifying Windscreen Wiper Arms Cap And Removal Direction
Unfasten nut.
For tightening torque refer to 61 61 11AZ in 61 61 WINDSCREEN WIPERS .

2007 BMW 335i
Fig. 324: Identifying Windscreen Wiper Arms Nut

IMPORTANT: Do not bend windscreen wiper arm during removal (risk of breakage).
Detach windshield wiper arm with special tool 61 6 210.

Adjust position of wiper arm in question in rest position (measured between wiper lip and top edge of cowl
panel cover).
Then tighten down wiper arm and check Adjustment Dimensions of relevant wiper arm again.
Reference points (A, B) are the mountings of the wiper blades on the wiper arms to the sealing lip (1) of the
cowl panel.
Contact angle (C) is the angle between wiper blade center plane (2) and windscreen.
For tightening torque refer to 61 61 11AZ in 61 61 WINDSCREEN WIPERS .

2007 BMW 335i
Fig. 326: Identifying Angle Between Wiper Blade Centre Plane And Windscreen
61 61 270 REMOVING AND INSTALLING/REPLACING BRACKET FOR WINDSCREEN WIPER

SYSTEM COMPLETE WITH MOTOR
 Remove both wiper arms

 Remove Lower Section Of Microfilter Housing
 Remove Cowl Panel Cover
 Remove both Tension Struts from spring strut dome
Release screws (2) from left heater bulkhead (3).
Remove left heater bulkhead (3) towards top.
Unclip cable (1) for wiper motor from holder.
Release screws (5) for wiper bracket (4).
Tightening torque, 61 61 6AZ in 61 61 WINDSCREEN WIPERS .
Remove wiper bracket (4) upwards.
Disconnect plug for wiper motor.

2007 BMW 335i
Fig. 327: Identifying Screws, Left Heater Bulkhead, Wiper Bracket And Cable
Installation:
Rubber mount (1) and rubber guide (3) must not be missing.
Rubber guide (3) must be correctly seated in guide (2).
Fig. 328: Identifying Rubber Mount And Rubber Guide

Installation:
Before fitting the wiper arms, allow the windscreen wiper motor to run in to the rest position.
To ensure that the windscreen wiper system functions properly, Check/Adjust the contact angle of the wiper
arms to the windscreen.
HEADLIGHT WASHER SYSTEM

2007 BMW 335i

61 67 010 REMOVING AND INSTALLING/REPLACING WASHER PUMP OF HEADLIGHT

WASHER SYSTEM
NOTE: Drain fluid reservoir for windscreen washer system.
 Remove right Wheel Arch Cover

Open split pin (3) and detach hose (2) from washer pump of headlight cleaning system (4).
If necessary, turn washer pump of headlight cleaning system (4) and pull out of fluid reservoir for windscreen
washer system (5).
2007 BMW 335i
Fig. 330: Identifying Split Pin, Hose, Washer Pump, Plug Connection Fluid Reservoir And Removal
Direction
Installation:
Coat sealing ring of washer pump for headlight cleaning system with antiseize agent.
Ensure hose is laid without kinks.
61 67 083 REMOVING AND INSTALLING / REPLACING LEFT OR RIGHT HIGH-PRESSURE

NOZZLE OF HEADLIGHT WASHER SYSTEM
 13 3 010
To prevent excessive escape of washer fluid, seal off end of high-pressure line with special tool 13 3 010.
2007 BMW 335i

Unlock catch (1) in direction of arrow.
Remove high-pressure nozzle (2) towards rear from headlight arm (3).
Unlock high-pressure line and detach from high-pressure nozzle.
Installation:
Keep plug connection for high-pressure nozzle (2) and high-pressure line clean and free from grease.
Fig. 332: Identifying High-Pressure Nozzle, Headlight Arm, Catch And Removal Direction
Installation:
Ensure that guide (2) is correctly seated.
Make sure retaining lugs (1) engage correctly.
Carry out a function test before fitting bumper trim.
If necessary, adjustment can be carried out carefully using pointed pliers (tape of front area with adhesive tape
where necessary).
2007 BMW 335i
Fig. 333: Identifying Retaining Lugs And Guide

WINDOW WASHER SYSTEM

2007 BMW 335i

61 71 015 REMOVING AND INSTALLING/REPLACING A SPRAY NOZZLE IN WINDSCREEN

WASHER SYSTEM
NOTE: The jet nozzles of the windscreen washer system are preset at the factory and
cannot be readjusted.
 Remove Lower Section Of Microfilter Housing
Press detent lug (1).
Detach unlocked plug housing (2) in direction of arrow.
Detach hose (3) from spray nozzle.
Fig. 335: Identifying Plug Housing, Lug, Hose And Removal Direction
Release spray nozzle (1) in direction of arrow from cowl panel cover and remove.
Installation:
Make sure spray nozzle (1) is correctly seated.

2007 BMW 335i
Fig. 336: Identifying Spray Nozzle And Removal Direction

Installation:
Following parts of spray nozzle (4) must not be damaged or missing:
Fig. 337: Identifying Spray Nozzle, Plug Connection, Hose Connection And Lugs
61 71 061 REPLACING FLUID RESERVOIR FOR WINDSCREEN WASHER SYSTEM
 Remove front right Auxiliary Turn Indicator Light

 Remove right Front Wheel
Clip cable holders (1) out of mounting.
Clip hose (2) out of mounting.

2007 BMW 335i
Unlock filler hose (4) and detach from fitting on fluid reservoir (5).
NOTE: Catch any escaping washer fluid if necessary.
Release screw (3).
Pull flu id reservoir (5) forwards.
Fig. 338: Identifying Fluid Reservoir, Hose, Filler Hose, Screw And Cable Holders
Installation:
Retaining lugs (1) of fluid reservoir must be correctly seated in tabs (2).
Fig. 339: Identifying Retaining Lugs And Tabs

Unlock and disconnect all plug connections.
Remove Level Switch (1).

2007 BMW 335i
Remove Windscreen Washer Pump (2).
If necessary, remove Washer Pump For Headlight Washer System (3).
Remove washer reservoir.
Fig. 340: Identifying Washer Pumps And Level Switch

Installation:
 Replace strainers on washer pumps

 Coat sealing rings of washer pumps with antiseize agent
 Lay lines of washer pumps without kinks and clip in to holders on fluid tank
 Fill flu id tank for windscreen washer system
61 71 100 REMOVING AND INSTALLING/REPLACING WINDSCREEN WASHER PUMP
NOTE: Drain fluid reservoir for windscreen washer system.

Detach hose from windscreen washer pump (1).
Turn windscreen washer pump (1) if necessary and pull in direction of arrow out of fluid reservoir for
windscreen washer system.
2007 BMW 335i
Fig. 341: Identifying Windscreen Washer Pump, Plug Connection And Removal Direction
Installation:
Coat sealing ring of windscreen washer pump with antiseize agent.
Ensure hose is laid without kinks.

2007 BMW 335i
HVAC Heating and Air Conditioning - Repair Instructions
HVAC
Heating and Air Conditioning - Repair Instructions
GENERAL INFORMATION

function is active.

Fig. 1: Identifying MSA Button

 Workshop mode
2007 BMW 335i
A = 10 mm
B = 7 mm
Fig. 2: Identifying Basic Setting For Engine Hood/Bonnet

64 0... DISCONNECTING A WATER HOSE
 13 3 010
When removing water hoses which are located in the upper area of the cooling system, disconnecting them
prevents a large-scale escape of coolant.
Fit special tool 13 3 010 as illustrated to water hose (1).
Disconnect water hose (1) by turning nut (2) in direction of arrow.

2007 BMW 335i
Fig. 3: Water Hose, Nut, Special Tool (13 3 010) And Removal Direction
HEATER WITH OPERATION

64 53... OVERVIEW OF A/C CIRCUIT COMPONENTS
2007 BMW 335i
Fig. 4: Overview Of A/C Circuit Components

64 11... OVERVIEW OF SERVODRIVES ON HEATER/AIR CONDITIONER

2007 BMW 335i
Fig. 5: Locating Servodrives On Heater/Air Conditioner Assembly

64 11 206 REMOVING AND INSTALLING/REPLACING HEATER
WARNING: Avoid contact with refrigerant and refrigerant oil.
Follow safety instructions for handling refrigerant R 134a.
Follow safety instructions for handling refrigerant oil.
WARNING: Follow instructions for working on cooling system.
Restart engine only when A/C system has been correctly filled.
2007 BMW 335i
NOTE: If A/C system is opened for more than 24 hours: Replace desiccant insert for
A/C system
 Draw off refrigerant from A/C system

 Remove expansion valve
 Remove instrument panel trim
 Remove complete steering column
 Disconnect plug connection for control unit for car access system
WARNING: To avoid injury, cover holder (1) on support tube (2).
Fig. 6: Cover Holder And Support Tube

Release cover cap (1) from bulkhead (2).

2007 BMW 335i
Fig. 7: Cover Cap And Bulkhead

Release screw (1).
For tightening torque refer to 64 11 1AZ in 64 11 HOUSING, HEATER/AIR CONDITIONER .
Fig. 8: Screw
Detach right footwell heating duct (1) in area (2) in direction of arrow.
Detach right footwell heating duct (1) with adapter (3) from heater/air conditioner and remove in direction of
arrow from right rear compartment heating duct (4).
2007 BMW 335i
Fig. 9: Right Footwell Heating Duct, Area, Adapter, Right Rear Compartment Heating Duct And
Removal Direction
NOTE: Lower instrument panel trim partially shown.
Detach left footwell heating duct (1) in area (2) in direction of arrow.
Detach left footwell heating duct (1) with adapter (3) from heater/air conditioner and remove in direction of
arrow from left rear compartment heating duct (4).
Fig. 10: Left Footwell Heating Duct, Area, Adapter, Left Rear Compartment Heating Duct And Removal
Direction
Installation:
Make sure retainer (2) is correctly seated on left/right footwell heating duct (1).
Insert footwell heating duct (1) with adapter (3) in rear compartment heating duct (4).
2007 BMW 335i
Attach footwell heating duct (1) in area (4) to heater/air conditioner. Make sure assembly is locked exactly at
point (5).
Fig. 11: Heating Duct, Retainer, Adapter, Area And Rear Compartment Heating Duct
Unclip refrigerant line (3).
Feed out rubber grommet (4).
Installation:
Make sure rubber grommet (4) is correctly seated.
IMPORTANT: Carefully blow through aluminum triple pipe to remove remaining coolant from
heat exchanger for heating system.
Installation:
Vent cooling system and check for leaks.

2007 BMW 335i
Fig. 12: Refrigerant Line And Rubber Grommet

 Disconnect all necessary cable ties on support tube.

 Release wiring harnesses/cable ducts and lay to one side.
 If necessary, remove control units/disconnect plug connections.
Installation:
Make sure wiring harnesses/cable ducts are correctly routed and secured.
Release screw (1) of heater on support tube (2).
Fig. 13: Screw And Support Tube

2007 BMW 335i
Detach wiring harness (3) from support tube (2).
Release screws (1) of heater on support tube (2).
For tightening torque refer to 64 11 6AZ in 64 11 HOUSING, HEATER/AIR CONDITIONER .
Fig. 14: Wiring Harness, Support Tube And Screws

Release nuts (1) on right on support tube (2).
Fig. 15: Nuts And Support Tube (Right)

Release nuts (1) on left on support tube (2).
2007 BMW 335i
Fig. 16: Nuts And Left Support Tube

Release screw (1) on support tube (2).
Fig. 17: Screw And Support Tube

Release screws (1) on support tube (2) from bracket (3).
Detach support tube (2) and remove from vehicle with assistance of a second person.
2007 BMW 335i
Fig. 18: Screws, Support Tube And Bracket

Remove heater.
Installation:
Make sure heater (1) is correctly seated.
Installation:
Make sure condensate drain (1) is correctly seated in grommet (2).
Fig. 19: Heater And Grommet

64 11 208 REPLACING HEATER CORE
IMPORTANT: Determine manufacturer of installed heater (Denso or Behr) before ordering

spare parts!
2007 BMW 335i
Remove trim panel for pedal assembly .
Fig. 20: Heater (Denso Or Behr) Type

 Remove heater/air conditioner
Release screws (1).
Slide rubber grommet (1) with foam seal forward slightly.
Carefully feed pipe holder (3) with pipes (4) past rubber grommet (2).
Installation:
If necessary, replace rubber grommet (1) and/or foam seal.
Make sure rubber grommet (1) is correctly seated on pipe holder (3).
2007 BMW 335i
Fig. 21: Screws, Rubber Grommet, Pipe Holder, Pipes And Removal Direction
If necessary, remove coolant hose (2).
Release screws (3) and remove cover.
NOTE: Diesel version only:
Withdraw electric auxiliary heater (4) in direction of arrow.
Remove heater (5) from heater/air conditioner (6).
Fig. 22: Plug Connection, Coolant Hose, Screws, Heater, Electric Auxiliary Heater, Heater/Air
Conditioner And Removal Direction
Release screws (1) and slide screw clamps (2) forwards slightly.
2007 BMW 335i
Remove pipes (3) from heater core (4).
Installation:
Coat sealing rings with antiseize agent.
Make sure sealing rings are correctly seated.
Fig. 23: Screws, Screw Clamps, Pipes, Heater Core And Removal Direction
IMPORTANT: Inflow connection (3) may only be positioned at the bottom.
When installing, make sure that the return-flow connection (2) (larger opening)
marked with a black dot (1) is positioned at the top.
Inflow connection (3) accordingly may only be positioned at the bottom.

2007 BMW 335i
Fig. 24: Black Dot, Inflow Connection And Return-Flow Connection

64 11 212 REMOVING AND INSTALLING/REPLACING HEATER/AIR CONDITIONER FAN
 Remove trim for instrument panel, bottom right

 Partially release air duct at side

Carefully raise lug (1) and feed out housing (2) by turning clockwise.
Installation:
Lug (1) must not be damaged and must snap audibly into place.
2007 BMW 335i
Fig. 26: Lug, Housing And Removal Directions

Replacement:
Replace controller for heater/air conditioner fan
64 11 224 REPLACING CONTROLLER FOR HEATER/AIR CONDITIONER FAN
 Remove fan for heater/air conditioner
Release screws (2) and remove controller.
Fig. 27: Plug Connection And Screws

2007 BMW 335i
64 11 273 REPLACING WATER VALVE FOR HEATER
WARNING: Danger of scalding! Work on the cooling system should only be carried
out when the engine has cooled down.
Follow instructions for working on cooling system!
NOTE: Disconnect coolant hoses on water valve.
Recycling
Coolant emerges when coolant lines are detached. Have a suitable collecting container ready.
Catch and dispose of emerging coolant.
 Release oil reservoir from bracket and place to one side
Release hose clamps (2) and remove hoses.
Remove water valve (3) from mounting (4).
Fig. 28: Plug Connection, Hose Clamps, Water Valve And Mounting
Installation:
To avoid the buildup of noise, make sure that the rubber mounts on the water valve are securely seated in the
2007 BMW 335i
mounting (2) on the frame side member.
Fig. 29: Mounting

After installation:
 Fill and vent cooling system and check for leaks
64 11 377 REMOVING AND INSTALLING/REPLACING HEATER/AIR CONDITIONER

OPERATOR UNIT (VERSION WITHOUT CCC/ASK)
 00 9 340
Protection)!
NOTE: C ar C ommunication C omputer (CCC)
A udio S ystem K ontroller / Controller (ASK)
Lever out heater/air conditioner operator unit (1) with special tool 00 9 340 and pull.
Disconnect associated plug connections.
Remove heater/air conditioner operator unit (1) complete with center console switch cluster (2) and trim (3).
2007 BMW 335i
Fig. 30: Heater/Air Conditioner Operator Unit, Center Console Switch Cluster, Trim, Special Tool 00 9
340 And Removal Direction
Replacement:
Carefully unclip operator unit trim (1) at inner retaining points (2) only.
IMPORTANT: Risk of damage to operator unit (3)!
Fig. 31: Operator Unit Trim, Retaining Points And Operator Unit
Carefully unclip operator unit trim (1) at outer retaining points (2) only.
Remove trim (1) from operator unit (3).

2007 BMW 335i
Fig. 32: Trim, Retaining Points And Operator Unit

Replacement:
Carry out programming/coding.
64 11 378 REMOVING AND INSTALLING/REPLACING HEATER/AIR CONDITIONER

OPERATOR UNIT (VERSION WITH CCC/ASK)
 00 9 340
Protection)!
NOTE: C ar C ommunication C omputer (CCC)
A udio S ystem K ontroller / Controller (ASK)
 Remove right decorative trim on instrument panel
NOTE: Unclip the heater/air conditioner operator unit (2) by simultaneously
 levering out using special tool 00 9 340

 pulling on the relevant control button (3).
Fit special tool 00 9 340 on either side as illustrated.

2007 BMW 335i
Unclip heater/air conditioner operator unit (2) complete with trim (1) at fastening points (4) and pull back.
Remove heater/air conditioner operator unit (2) complete with trim (1).
Fig. 33: Trim, Heater/Air Conditioner Operator Unit, Control Button, Fastening Points And Special Tool
(00 9 340)
Replacement:
Carefully unclip operator unit trim (1) at inner retaining points (2) only.
IMPORTANT: Risk of damage to operator unit!
Fig. 34: Operator Unit Trim And Retaining Points

Carefully unclip operator unit trim (1) at outer retaining points (2) only.
2007 BMW 335i
Remove trim (1) from operator unit (3).
IMPORTANT: Risk of damage to operator unit (3)!
Fig. 35: Operator Unit Trim, Retaining Points And Trim

Replacement:
Carry out programming/coding.
64 11 806 REMOVING AND INSTALLING/REPLACING SERVODRIVE FOR FRESH-

/RECIRCULATED-AIR FLAP
IMPORTANT: Servomotors must be re-addressed in the event of replacement!
Addressing can only be carried out with the BMW diagnosis system.
Service functions:
 Body
 Heating and A/C function
 Flap motors
 Re-address flap motors
 Remove right glovebox with housing
Release screws (2).

2007 BMW 335i
Detach servodrive for fresh-/recirculated-air flap (3) in direction of arrow from heater/air conditioner.
Installation:
Place servodrive for fresh-/recirculated-air flap (3) exactly on associated gear teeth.
Fig. 36: Plug Connection, Fresh-/Recirculated-Air Flap, Screws And Removal Direction
64 11 829 REPLACING SERVODRIVE FOR VENTILATION FLAPS (AUTOMATIC A/C)
Service functions:
 Body
 Flap motors
Release screws (2).
Detach servodrive for ventilation flaps (3) in direction of arrow from heater/air conditioner (4).
2007 BMW 335i
Installation:
Place servodrive for ventilation flaps (3) over guide pin (5).
Fig. 37: Ventilation Flaps Servodrive, Heater/Air Conditioner, Guide Pin, Screws, Plug Connection And
Removal Direction
64 11 839 REPLACING SERVODRIVE FOR FOOTWELL FLAP (AUTOMATIC A/C)
Service functions:
 Body
 Flap motors
2007 BMW 335i
Fig. 38: Right Footwell Heating Duct, Area, Adapter, Right Rear Compartment Heating Duct And
Removal Direction
Release screws (2) and (3).
Detach bracket (4) complete with servodrives from heater/air conditioner (5).
Installation:
Make sure bracket (4) is correctly seated on heater/air conditioner (5).
Fig. 39: Plug Connection, Screws, Bracket, Heater/Air Conditioner And Removal Direction
Release screws (1).
Remove servodrive for footwell flap (2) from bracket (3).

2007 BMW 335i
Installation:
Place servodrive for footwell flap (2) over guide pin (4).
Fig. 40: Screws, Footwell Flap, Bracket And Guide Pin

64 11 850 REPLACING SERVODRIVE FOR REAR COMPARTMENT FLAP
Service functions:
 Body
 Flap motors
 Remove trim for instrument panel, bottom right
Release screws (2).
Detach servodrive for rear compartment flap (3) in direction of arrow from heater/air conditioner (4).
Installation:
2007 BMW 335i
Place servodrive for rear compartment flap (3) exactly onto heater/air conditioner (4).
Fig. 41: Rear Compartment Flap Servodrive, Heater/Air Conditioner, Screws, Plug Connection And
Removal Direction
64 11 856 REMOVING AND INSTALLING / REPLACING SERVODRIVE FOR CENTRAL

KINEMATICS (A / C CONTROL)
Service functions:
 Body
 Flap motors
2007 BMW 335i
Fig. 42: Right Footwell Heating Duct, Adapter, Right Rear Compartment Heating Duct And Removal
Direction
Release screws (2).
Detach servodrive for central kinematics (3) in direction of arrow from heater/air conditioner (4).
Installation:
Place servodrive for central kinematics (3) over guide pin (5).
Fig. 43: Central Kinematics Servodrive, Heater/Air Conditioner, Screws, Plug Connection And Removal
Direction
64 11 866 REMOVING AND INSTALLING/REPLACING SERVODRIVE FOR BLENDING FLAP

(LEFT)
2007 BMW 335i
Service functions:
 Body
 Flap motors
 Remove trim panel for pedal assembly.
NOTE: For purposes of clarity, the following graphics show the heater/air conditioner
removed.
Release screws (2).
Remove servodrive at side.
Installation:
Do not twist teeth of servodrive.

64 11 868 REMOVING AND INSTALLING/REPLACING SERVODRIVE FOR DEFROSTING FLAP

2007 BMW 335i
(RIGHT)
Service functions:
 Body
 Flap motors
 Remove glovebox with housing
removed.
Release screws (2).
Remove servodrive at side.
Installation:
Do not twist teeth of servodrive.

2007 BMW 335i
64 11 869 REPLACING SERVODRIVE FOR BLENDING FLAP
Service functions:
 Body
 Flap motors
Release screws (2).
Detach servodrive for blending flap (3) in direction of arrow from heater/air conditioner (4).
Installation:
Place servodrive for blending flap (3) over guide pin (5).
Fig. 46: Blending Flap Servodrive, Heater/Air Conditioner, Guide Pin, Screws, Plug Connection And
Removal Direction

2007 BMW 335i
(LEFT)
Service functions:
 Body
 Flap motors
 Remove trim for instrument panel at bottom left

 E90/E91/E92/E93 :
 Remove panel for pedal assembly
NOTE: Lower instrument panel trim partially shown transparent.
Detach left footwell heating duct (1) in area (2) in direction of arrow.
Detach left footwell heating duct (1) with adapter (3) from heater/air conditioner and remove in direction of
arrow from left rear compartment heating duct (4).
Fig. 47: Left Footwell Heating Duct, Adapter, Area, Left Rear Compartment Heating Duct And Removal
Direction
Installation:
2007 BMW 335i
Make sure retainer (2) is correctly seated on left footwell heating duct (1).
Insert left footwell heating duct (1) with adapter (3) in left rear compartment heating duct (4).
Attach left footwell heating duct (1) in area (4) to heater/air conditioner. Make sure assembly is locked exactly
at point (5).
Fig. 48: Left Footwell Heating Duct, Retainer, Adapter, Area And Left Rear Compartment Heating Duct
Release screws (2).
Installation:
Fig. 49: Blending Flap Servodrive, Screws, Heater/Air Conditioner, Plug Connection, Guide Pin And
2007 BMW 335i
Removal Direction

(RIGHT, AUTOMATIC A/C)
Service functions:
 Body
 Flap motors

 E87 only:
 Remove storage compartment
Fig. 50: Right Footwell Heating Duct, Adapter, Area, Right Rear Compartment Heating Duct And
Removal Direction
2007 BMW 335i
Installation:
Make sure retainer (2) is correctly seated on right footwell heating duct (1).
Insert right footwell heating duct (1) with adapter (3) in right rear compartment heating duct (4).
Attach right footwell heating duct (1) in area (4) to heater/air conditioner. Make sure assembly is locked exactly
at point (5).
Fig. 51: Right Footwell Heating Duct, Retainer, Adapter, Area And Right Rear Compartment Heating
Duct
Release screws (2).
Installation:
2007 BMW 335i
Fig. 52: Blending Flap Servodrive, Screws, Plug Connection, Guide Pin, Heater/Air Conditioner And
Removal Direction
64 11 905 REMOVING AND INSTALLING/REPLACING VENTILATION TEMPERATURE SENSOR
 Remove decorative strip on instrument panel on right
removed.
Pull temperature sensor (1) out of retaining lug (2).
Installation:
Make sure rubber ring is correctly seated.
Fig. 53: Temperature Sensor And Retaining Lug

2007 BMW 335i
Disconnect plug connection (1) and remove temperature sensor (2).
Fig. 54: Plug Connection And Temperature Sensor

64 11 908 REMOVING AND INSTALLING/REPLACING FOOTWELL TEMPERATURE SENSOR
NOTE: For purposes of clarity, the following graphic shows the heater/air conditioner
removed.
Remove air routing duct (1) and unscrew temperature sensor (2).
Fig. 55: Air Routing Duct And Temperature Sensor

64 11 942 REPLACING EVAPORATOR TEMPERATURE SENSOR

2007 BMW 335i
 Remove lower instrument panel trim
Withdraw temperature sensor (2).
Installation:
Ensure temperature sensor (2) is correctly seated.
Fig. 56: Plug Connection And Temperature Sensor

64 11 970 REPLACING FOGGING SENSOR
 00 9 317
WARNING: Make sure rooms are well ventilated when working with adhesive remover
indoors.
IMPORTANT: Do not under any circumstances use paint thinner to clean the bonding
surface.
 Remove two-part mirror base cover

2007 BMW 335i
NOTE: If necessary, carefully heat fogging sensor (2) with a hot air blower to approx.
40-60°C.
Lift off fogging sensor (2) with special tool 00 9 317 and slowly pull off from windshield.
Installation:
Bonding surface must be dry and free of dust and grease.
Clean bonding surface with adhesive remover (sourcing reference: BMW Parts Service).
After cleaning, do not touch bonding surface with bare hands.
Fig. 57: Plug Connection, Fogging Sensor And Special Tool (00 9 317)
Pull off protective film completely from fogging sensor (3).
Place mounting template (1) as pictured on rain sensor (2).
Press fogging sensor (3) in direction of arrow with a contact pressure of > or =15 N/cm 2 onto inside of
windshield.
NOTE: Firm thumb pressure attains approx. 30 N/cm2 .
Remove mounting template (1) carefully from fogging sensor (3).

2007 BMW 335i
Fig. 58: Mounting Template, Rain Sensor And Fogging Sensor

64 11 991 REMOVING AND INSTALLING/REPLACING SENSOR FOR AUTOMATIC

RECIRCULATED AIR CONTROL
Turn sensor for automatic recirculated air control (2) upwards and in direction of arrow and remove from
mounting (3).
Installation:
Make sure sensor for automatic recirculated air control (2) is correctly seated in mounting (3).
Fig. 59: Plug Connection, Automatic Recirculated Air Control Sensor, Mounting And Removal Direction
64 11 992 REMOVING AND INSTALLING/REPLACING SOLAR SENSOR

2007 BMW 335i
 00 9 340
Lever out solar sensor (1) with special tool 00 9 340 in direction of arrow.
NOTE: Secure disconnected wiring harness of solar sensor (1) against falling out
below instrument panel trim (2).
Disconnect associated plug connection and remove solar sensor (1) from instrument panel trim (2).
Fig. 60: Solar Sensor, Instrument Panel Trim, Special Tool (00 9 340) And Removal Direction
AUXILIARY HEATER WITH CONTROL ELEMENTS

64 12... INITIALIZING TELESTART HAND-HELD TRANSMITTER (T90) (UP TO BUILD DATE
03/2007)
NOTE: The Telestart hand transmitter must be initialized when:
 Hand transmitter is replaced

 Car Access System control unit is replaced
The independent heating is switched on under an outside temperature of

approx. 15°C with the hand transmitter and at a preselected switch-on time.
Direct activation is possible at any outside temperature via the "Climate" menu
item in the i-Drive, but not in driving mode.
To initialize a new hand transmitter, perform the following operations from inside the vehicle:
2007 BMW 335i
 Close all vehicle doors

 Within 5 seconds: Switch ignition lock from terminal "0" to terminal "R" and then back to terminal "0"
 Within 5 seconds: Press OFF button (1) on hand transmitter and with OFF button (1) held down press ON
button (2) three times quickly
 Release both buttons. LED (3) on hand transmitter flashes
Fig. 61: OFF Button, ON Button And LED

NOTE: The vehicle's central locking closes and opens automatically on successful
initialization.
The initialization process must be repeated if there is no checkback signal from

the central locking system.
64 12... INITIALIZING TELESTART HAND-HELD TRANSMITTER (T93) (FROM BUILD DATE

03/2007)
NOTE: The Telestart hand transmitter must be initialized when:
 Hand transmitter is replaced

 Car Access System control unit is replaced
The independent heating is switched on under an outside temperature of

approx. 15°C with the hand transmitter and at a preselected switch-on time.
Direct activation is possible at any outside temperature via the "Climate" menu
item in the i-Drive, but not in driving mode.
To initialize a new hand transmitter, perform the following operations from inside the vehicle:
 Close all doors on vehicle (vehicle must be unlocked!)

2007 BMW 335i
 Within 5 seconds: Turn ignition lock from terminal "0" to terminal "R" and then back to terminal "0" (by
inserting and removing key, insertion duration: 1 to 5 secs.)
 Within 5 seconds: Simultaneously press both buttons (1, 2) on hand transmitter until LED (3) lights up
orange.
 Release both buttons. Briefly press ON button (1) three times within 10 seconds; LED (3) flashes orange
as confirmation.
Fig. 62: Telestart Hand Transmitter And Buttons

NOTE: The vehicle's central locking closes and opens automatically on successful
initialization.
The initialization process must be repeated if there is no checkback signal from

the central locking system.
64 12... INSTALL FUEL INTAKE LINE WITH FILTER
IMPORTANT: Observe country-specific safety regulations.
Ensure adequate ventilation in the place of work!
Avoid skin contact (wear gloves)!

2007 BMW 335i
Recycling
Fuel escapes when fuel lines are detached. Have a suitable collecting container ready.
 Remove rear seat bench
NOTE: 1. Fuel intake line without filter

2. Fuel intake line with filter
Fig. 63: Fuel Intake Line Without Filter And Fuel Intake Line With Filter
Fold back floor panelling (1) on right.
2007 BMW 335i
Fig. 64: Panelling, Screws And Cover


Pull fuel line (2) out of fuel intake line.
Pull fuel intake line (4) out of connection piece in service cover.
Install new fuel intake line with filter.

2007 BMW 335i
Fig. 66: Hose Clips, Fuel Line, Fuel Intake Line And Removal Direction
Installation:
Push fuel line (1) up to beading (2) in grommet of fuel intake line (3).
Fuel line (1) and fuel intake line (3) must be pushed into the grommet so that they join.
Fig. 67: Fuel Line, Beading And Fuel Intake Line

Installation:
Secure spacer (1) on fuel intake line.
NOTE: Connection beading (2) and tabs (3) of hose clips must be positioned
horizontally.
2007 BMW 335i
Fig. 68: Spacer, Beading And Tabs

64 12 089 REMOVING AND INSTALLING OR REPLACING MUFFLER/SILENCER
Work on independent heating may only be carried out when it has cooled
down.
Release screws (1, 2) and remove muffler/silencer (3).
For tightening torque refer to 64 12 1AZ in 64 12 INDEPENDENT HEATER .
Fig. 69: Muffler/Silencer And Screws

2007 BMW 335i
64 12 120 REMOVING AND INSTALLING/REPLACING INTAKE MUFFLER FOR

INDEPENDENT/AUXILIARY HEATER
down.
Release retainer (1) and unscrew muffler (2) from connecting hose (3) in direction of arrow.
Installation:
Intake muffler (2) must be replaced if retainer (1) is damaged.
Fig. 70: Retainer, Muffler, Connecting Hose And Removal Direction

64 12 160 REMOVING AND INSTALLING OR REPLACING COMPLETE INDEPENDENT HEATER

WITH BRACKET
down.
Recycling
2007 BMW 335i
 Drain coolant from radiator

 Remove front left wheel arch trim
NOTE: For purposes of clarity, graphic shows front bumper removed.

Disconnect coolant hoses (1) and catch coolant in a suitable container.
Release screw (2).
Release fuel line (3) and catch escaping fuel in a suitable container.
Release nuts (4) and remove complete independent heater bracket.

2007 BMW 335i
Fig. 72: Coolant Hoses, Screws, Fuel Line And Nuts

When replacing independent heater without bracket:
Unclip retainer of intake silencer.
Turn metal tube (1) clockwise and remove intake silencer.
Release screws (2) and remove silencer (3).
Install fuel intake line with filter.
Fig. 73: Metal Tube, Screws And Silencer

Remove coolant hoses (1) and feed out of bracket.

2007 BMW 335i
Installation:
Risk of damage!
Make sure abrasion guard (2) is correctly seated.
Fig. 74: Coolant Hoses And Abrasion Guard

Release screws (2) and remove independent heater from bracket (3).
Fig. 75: Plug Connection, Screws And Bracket

WARNING: Diesel vehicles only:

2007 BMW 335i
Independent heaters many only be operated with the associated fuel

pump.
In the event of incorrect installation, fuel can escape and black smoke can
be issued when the independent heater is started.
Because of different build dates, installed fuel pumps must be checked.
Read out the heater number via the BMW DIS system and use this number
to determine the associated fuel pump from the table below.
Determine fitted fuel pump model and if necessary install new fuel pump.
NOTE:
FUEL PUMP REFERENCE CHART

Build date up to 09/2006 Build date from 09/2006
Heater number: 6 974 470 9 112 792
DP40: 6 951 678 DP41: 6 979 466
Fuel pump:
(black housing) (grey housing + yellow warning sticker)
After installation:
 Vent cooling system
64 12 600 REMOVING AND INSTALLING OR REPLACING FUEL PUMP
 13 3 010
Diesel only:
WARNING: Bear in mind the heater number when replacing the fuel pump
(independent heating metering pump).
For this purpose, read out the heater number via the BMW DIS system
and use this number to select the associated fuel pump from the table
below.
In the event of incorrect installation, fuel can escape and black smoke can
be issued when the independent heater is started.
NOTE:
2007 BMW 335i
FUEL PUMP REFERENCE CHART

Build date up to 09/2006 Build date from 09/2006
Heater number: 6 974 470 9 112 792
DP40: 6 951 678 DP41: 6 979 466
Fuel pump:
(black housing) (grey housing + yellow warning sticker)
 Remove left underbody panelling
Seal off water hoses at fuel pump with special tool 13 3 010.
Fig. 76: Special Tool (13 3 010) Onto Water Hoses

Recycling
Release screw (1).

2007 BMW 335i
Fig. 77: Screws

Release hose clamps (2) and detach fuel hoses.
Disengage rubber retainers (3).
NOTE: Secure fuel pump (4) against falling out.
Installation:
Observe direction of flow of fuel pump (4).
Fig. 78: Plug Connection, Hose Clamp, Rubber Retainers And Fuel Pump
NOZZLE AND OUTLETS

2007 BMW 335i
64 22... REMOVING AIR DUCTS
Detach right footwell heating duct (1) in area (2) in direction of arrow. Detach right footwell heating duct (1)
with adapter (3) from heater/air conditioner and remove in direction of arrow from right rear compartment
heating duct (4).
Fig. 79: Detach Right Footwell Heating Duct (1) In Area (2) In Direction Of Arrow
NOTE: Lower instrument panel trim partially shown.
Detach left footwell heating duct (1) in area (2) in direction of arrow. Detach left footwell heating duct (1) with
adapter (3) from heater/air conditioner and remove in direction of arrow from left rear compartment heating
duct (4).
Fig. 80: Detach Left Footwell Heating Duct (1) In Area (2) In Direction Of Arrow
Installation: Make sure retainer (2) is correctly seated on left/right footwell heating duct (1). Insert footwell
heating duct (1) with adapter (3) in rear compartment heating duct (4). Attach footwell heating duct (1) in area
2007 BMW 335i
(4) to heater/air conditioner. Make sure assembly is locked exactly at point (5).
Fig. 81: Installing Air Duct

64 22 137 REMOVING AND INSTALLING/REPLACING LEFT FRESH-AIR GRILL
 Removing decorative strip on instrument panel on left (replacement).
64 22 138 REMOVING AND INSTALLING/REPLACING RIGHT FRESH-AIR GRILL
Lever out catches (2) and unclip right fresh-air grill (1) from right decorative strip on instrument panel (3).
Fig. 82: Right Fresh-Air Grill, Catches, Instrument Panel And Removal Direction
2007 BMW 335i
64 22 162 REMOVING AND INSTALLING/REPLACING CENTER FRESH-AIR GRILL
Release nuts (1) and remove center fresh-air grill (2) from decorative strip on instrument panel on right (3).
Fig. 83: Center Fresh-Air Grill, Instrument Panel Right Decorative Strip, Nuts And Removal Direction
64 22 191 REMOVING AND INSTALLING/REPLACING REAR COMPARTMENT FRESH-AIR

GRILLE
 Remove front section of rear console trim
Release screws (1) and remove trim (2) from air duct (3).
2007 BMW 335i
Fig. 84: Screws, Trim And Air Duct

Installation:
Guide air duct (1) in direction of arrow downwards.
Feed guide (2) into lug (3).
Fig. 85: Air Duct, Guide, Lug And Removal Direction

MICROFILTER
64 31 011 REPLACING MICROFILTER FOR INTERIOR VENTILATION
 Remove microfilter housing (upper section)

2007 BMW 335i
Release microfilter (2) in direction of arrow from upper section of housing (3).
Installation:
Make sure microfilter (2) is correctly seated.
Fig. 86: Catches, Microfilter, Upper Section Of Housing And Removal Direction
64 31 062 REMOVING AND INSTALLING/REPLACING LEFT LOWER MICROFILTER HOUSING

SECTION
 Remove upper section of microfilter housing
Release screws (1).
Pull out rubber tab (2).
Remove cover (3) and remove lower microfilter housing section (4).
Installation:

2007 BMW 335i
Fig. 87: Identifying Rubber Tab And Cover

Installation:
Retaining lugs (1) must be correctly inserted in cowl panel (2).
Fig. 88: Identifying Lugs And Cowl Panel

64 31 063 REMOVING AND INSTALLING/REPLACING RIGHT LOWER MICROFILTER

HOUSING SECTION
 Remove right upper microfilter housing section
Release screw (1).
Pull off rubber tabs (2) and remove cover (3).

2007 BMW 335i
Unclip AUC sensor (4) with electrical lead and remove lower microfilter housing section.
Installation:
Fig. 89: Identifying Rubber Tabs And Cover

Installation:
Retaining lugs (1) must be correctly inserted in cowl panel (2).
Fig. 90: Identifying Lugs And Cowl Panel

64 31 072 REMOVING AND INSTALLING/REPLACING LEFT UPPER MICROFILTER HOUSING

SECTION
Release screws (1).

2007 BMW 335i
Remove upper microfilter housing section (2) and if necessary disconnect plug connection for bonnet/hood
contact switch (3).
Installation:
Make sure upper microfilter housing section is correctly seated.
Fig. 91: Identifying Upper Microfilter Housing Section And Hood Contact Switch
Replacement:
 Modify hood/bonnet contact switch. See REMOVING AND INSTALLING/REPLACING ENGINE

HOOD CONTACT SWITCH .
 Modify microfilter for interior ventilation.
64 31 074 REMOVING AND INSTALLING/REPLACING RIGHT UPPER MICROFILTER HOUSING

SECTION
Release screws (1) and remove upper microfilter housing section (2).
Installation:
Make sure upper microfilter housing section is correctly seated.

2007 BMW 335i
Fig. 92: Identifying Upper Microfilter Housing Section And Screw

Replacement:
Replace microfilter for interior ventilation.
64 31 081 REMOVING AND INSTALLING/REPLACING MICROFILTER HOUSING (UPPER

SECTION)
Release screws (1).
Unfasten screws (2 and 3).
Remove upper section of microfilter housing (4).
Installation:
Make sure upper section of microfilter housing (4) is correctly seated.

2007 BMW 335i
Fig. 93: Screws And Microfilter Housing Upper Section

Replacement:
Release microfilter (2) in direction of arrow from upper section of housing (3).
Installation:
Make sure microfilter (2) is correctly seated.
Fig. 94: Catches, Microfilter, Upper Section Of Housing And Removal Direction
64 31 092 REMOVING AND INSTALLING/REPLACING MICROFILTER HOUSING (LOWER

SECTION)
 Remove upper section of microfilter housing
Release holder (1).
Remove right cover (2).
Installation:
Make sure right cover (2) is correctly seated.

2007 BMW 335i
Fig. 95: Holder, Catches And Right Cover

Left cover (4) is removed in same way as right cover.
Also for E90:
Release cable holder (2) and remove hose (1) from cover (4).
Installation:
Make sure cable holder (2) and hose (1) are correctly seated in opening (3).
Fig. 96: Hose, Cable Holder, Opening And Left Cover

Unclamp cable from guides (2).

2007 BMW 335i
Fig. 97: Identifying Plug Connection And Guides

Unclamp cable from guides (2).
Fig. 98: Identifying Connector And Cable Guides

Press detent lugs (3).
Release cable strip (1) in direction of arrow from lower section of microfilter housing (2).
Installation:
Detent lugs (3) must not be damaged or missing.
Make sure cable strip is correctly seated.

2007 BMW 335i
Fig. 99: Cable Strip, Detent Lugs, Microfilter Housing Lower Section And Removal Direction
Release holder (2) on both sides.
Release screw (1) on both sides on lower section of microfilter housing (3).
Fig. 100: Screws, Holder And Microfilter Housing Lower Section

Feed out microfilter housing lower section (1) in direction of arrow and remove.
Installation:
Make sure microfilter housing lower section (1) is correctly seated.

2007 BMW 335i
Fig. 101: Microfilter Housing Lower Section And Removal Direction

Installation:
Seal (2) of microfilter housing lower section (1) must not be damaged or missing.
Fig. 102: Microfilter Housing Lower Section And Seal

AIR CONDITIONING SYSTEM

64 50... A/C PERFORMANCE TEST (R 134A)
Before A/C efficiency test, satisfy following conditions:
1. Connect BMW diagnosis system. Check of the fault memory (no faults in the fault memory).
2. Attach a thermometer with separate display device to the head restraint and route the display device
wiring out of the passenger compartment outward.
2007 BMW 335i
3. Perform the test in a suitable workshop area with an ambient temperature above 18° C.
4. Vehicle temperature should be approximately the same as the ambient temperature in the workshop.
5. Engine must be at operating temperature.
Heat passenger compartment:
 A/C button is not activated during the heating process

 Close all windows and doors
 Set air recirculation function
 Select air distribution mode for footwell and defrosting
 On vehicles with CID: In A/C menu (CID) in Air distribution index tab: select 100 % footwell for driver
and front passenger and 100 % defrosting for driver (this applies here to driver and front passenger)
 Maximum temperature setting
 Maximum blower speed
 Start engine
Cool down passenger compartment:
Turn on air conditioning compressor with "A/C button" at a vehicle interior temperature of 45 °C (measured at
the head restraint).
On vehicles with MAX-AC button:
 Activation of MAX-AC (= maximum cooling power)
On vehicles without MAX-AC button:
 Set maximum cooling power by means of following steps:

 Setting minimum temperature
 Blower setting maximum
 Stratification maximum cold (4 blue bars)
 Only ventilation open
 Close remaining flaps (air outlet only from center fresh air grille, left and right)
After 5 minutes measure both ventilation temperatures with a thermometer at the same time (fresh air grille
center, left and right). The measured temperature must be no more than 16° C / 61° F and the difference
between right and left may not be greater than 2° C / 36° F.
If one or both temperature specifications is not reached: draw off heating and air conditioning system. Measure
amount of refrigerant drawn off.
If drawn-off quantity does not correspond to specified fill quantity : supplement refrigerant and repeat test.
2007 BMW 335i
If fill quantity is correct, continue troubleshooting by pressure measurement.
64 50... INSTALL THE RETROFIT ABSORBER FOR THE AIR CONDITIONING SUCTION LINE
The retrofit kit may be used for vehicles with a production date from 09/2008.
IMPORTANT: The retrofit kit with part number 6 987 991 may no longer be used!
Remove rear underbody protection
Unscrew nuts (1).
Remove the protective plate (2).
NOTE: Figure All-wheel drive vehicle
Fig. 103: Identifying Protective Plate And Nuts

Lay the steel measuring tape (2) onto the intake pipe (1).
IMPORTANT: The steel measuring tape (2) must be flush with the bottom of the rubber ring
(3)!
Mark distance A =11 cm.

2007 BMW 335i
Fig. 104: Identifying Steel Measuring Tape On Intake Pipe And Mark Distance
Attach the lower edge of the vibration absorber (1) at the marked position and screw it to the intake pipe (2).
Fig. 105: Identifying Steel Measuring Tape On Intake Pipe And Mark Distance
64 50... INSTRUCTIONS FOR HANDLING REFRIGERANT R 134A
WARNING: Although R 134a at normal temperature is non-toxic, non-flammable and

not explosive in air in any mixture ratio, it is still essential to follow
2007 BMW 335i
various safety precautions.
The filled refrigerant circuit of the A/C system is subject to gauge pressure. When carrying out repairs on the
A/C system, it is absolutely essential to draw off the refrigerant.
Do not weld or solder on filled A/C systems or in rooms into which R 134a may have leaked. Exposure to
flames or high temperatures (> or = 50°C) may give rise to toxic decomposition products (fluorine gas). For this
reason, do not smoke either.
R 134a must be drawn off, cleaned and returned to the A/C system with a service station following the relevant
operating instructions.
Avoid all contact with liquid or gaseous R 134a. Wear protective goggles and gloves when working on the
refrigerant circuit. R 134a acting on the skin can cause frostbite. Rinse affected body parts thoroughly with cold
water. If R 134a gets into your eyes, likewise rinse with plenty of water and, if necessary, remove contact lenses
if worn. Then seek immediate medical attention. Likewise seek immediate medical attention if you experience
problems after inhaling R 134a fumes.
As a gas, R 134a is colorless, odorless and heavier than air. If it gets into the atmosphere, this may result
especially in workshop pits in an imperceptible danger of asphyxiation or in cardiac palpitations. Ventilate
rooms adequately; if necessary, turn on installed extractor systems.
For a properly functioning A/C system, it is essential to have the greatest possible levels of cleanliness when
working on the A/C system and the best possible evacuation (at least 30 minutes dehumidification from
refrigerant circuit) before each filling of the A/C system.
R 134a absorbs moisture very easily. Therefore seal off opened pipes, condenser, evaporator, compressor and
drier bottle immediately with plugs.
With replacement parts, the plugs may only be removed immediately before the lines are connected.
In the event of warranty claims, the old parts must be provided with plugs to be able to determine the cause of
the damage.
If an A/C system has been completely drained by leakage, accident or repair, the drier element must be replaced
as excessive moisture may have entered the system.
Store filled pressurized refrigerant bottles in such a way that they are not exposed to direct sunlight or other heat
sources (max. 45°C). Also avoid exposing them to mechanical stress (e.g. by dropping).
In the event of fire, carbon dioxide (CO2), extinguishant powder and a sprayed water jet are deemed to be
suitable extinguishants. Cool reservoirs at risk with a sprayed water jet (risk of bursting!).
IMPORTANT: After each refill of an A/C system, check that protective caps of filling valves
are hand-tight. They serve as additional seals.
64 50... INSTRUCTIONS FOR HANDLING REFRIGERANT OIL (FOR REFRIGERANT R 134A)

2007 BMW 335i
WARNING: Observe the following points when handling refrigerant oil:
 Wear protective goggles.

 Wear gloves made from impermeable plastic.
 Do not swallow.
 Do not inhale.
Action to be taken after contact with refrigerant oil:
 After contact with eyes, rinse thoroughly with plenty of water and take out contact lenses (if worn). Then
seek immediate medical attention.
 After contact with the skin, wash body parts affected with plenty of soap and water.
 Do not induce vomiting if oil is swallowed, seek immediate medical attention.
 If inhaled, introduce the person affected to fresh air. Seek medical attention if problems persist.
WARNING: Refrigerant oil is non-combustible and non-explosive at normal

temperatures. In spite of this, the following precautions must be
observed:
 Do not store in the vicinity of flames, heat sources or strongly

oxidizing materials.
 Suitable extinguishants: carbon dioxide (CO2 ), dry extinguishant,
foam.
IMPORTANT: Refrigerant oil is hygroscopic and must therefore be stored in suitable

containers that are sealed airtight!
Recycling:
Dispose of drawn-off refrigerant oil as hazardous waste.
Absorb escaping refrigerant oil with fluid-binding material.
Notify the relevant authorities if larger amounts of refrigerant oil are discharged into above-ground water
supplies, drainage systems or subsoil.
64 53...INSTRUCTIONS FOR REPLACEMENT OF AIR CONDITIONING CAPACITORS AND

RADIATOR/COOLERS
See INSTRUCTIONS FOR REPLACEMENT OF AIR CONDITIONING CAPACITORS AND

RADIATOR/COOLERS.
2007 BMW 335i
64 50... LEAK TESTING WITH ULTRAVIOLET ADDITIVES (UV ADDITIVES) (BMW LEAK-
TESTING CASE)
IMPORTANT: It is absolutely essential to read and comply with the equipment manufacturer's
instructions for use provided in the equipment case!
Read and comply with the instructions for use provided with the special tool
particularly with regard to accident prevention, health protection and
environmental protection.
Use only BMW-approved UV-additives (e.g. TRACER).
Only the basic procedure is described in the following!
WARNING: Avoid contact with refrigerant.
Follow safety precautions when handling refrigerant.
IMPORTANT: UV lamp gets very hot in the radiation area!
Do not use the UV lamp without the filter glass.
Eyes and skin will suffer damage if the UV lamp is used without the filter glass.
When using the UV lamp, wear the protective goggles provided in the case.
NOTE:  Fill the hose system of the hand pump completely with UV additive PRIOR
to use
 Use the UV additive exclusively for BMW-approved refrigerant oils
 Do not operate the A/C system while the hand pump is connected or in use
 The A/C system must always be filled with an adequate amount of
refrigerant to enable the leak-detecting agent to be properly distributed
Before actually testing for leaks, check the entire refrigerant circuit using the UV leak-detecting lamp to ensure
that no AV additive is already in the area of the refrigerant circuit.
If already illuminated areas are found, carefully clean the area in question with the cleaning agent contained in
the case.
On initial use:
Connect hand pump (1) to additive cartridge (2) and hose piece (3).
2007 BMW 335i
Fig. 106: Hand Pump, Cartridge And Hose Piece

On initial use:
Attach vent valve (1) to quick-connect coupling (2).
Turn handle (3) on hand pump to advance the plunger until a small amount of UV additive emerges. This vents
the hose system.
IMPORTANT: The entire hand pump with hose system must not be disassembled again once
the filling work has been completed.
Fig. 107: Vent Valve, Quick-Connect Coupling, Handle And Installation Direction
Attach quick-connect coupling (1) to low-pressure connection (2) of A/C system.
Turn handle on hand pump (3) until the required amount of UV additive is added.
2007 BMW 335i
The quantity of UV additive to be added is dependent on the amount of refrigerant in the refrigerant circuit:
 A/C systems with refrigerant filling up to 900 g: one graduation mark (4) on additive cartridge
 A/C systems with refrigerant filling in excess of 900 g: two graduation marks (4) on additive cartridge
Fig. 108: Quick-Connect Coupling, Low-Pressure Connection, Hand Pump And Graduation Marks
NOTE: After filling, remove quick-connect coupling (1) and if necessary use the
cleaning agent contained in the special tool case to clean up the UV additive.
Further tasks:
 Start engine.
 Run A/C system at highest setting for 5-10 minutes in order to ensure adequate distribution of dye in the
system
 Switch off engine
 Check all A/C system components for possible leaks
 Possible leaks show up in luminous green
Complete accompanying information label (1) with the relevant data and attach in an easily visible position next
to the filling capacity information label (2).
2007 BMW 335i
Fig. 109: Capacity And Complete Information Labels

64 50... LEAK-TESTING WITH LEAK TESTER DEVICE
Refrigerant circuit is under high pressure!
Follow safety instructions for handling R 134a refrigerant.
Avoid contact with refrigerant and refrigerant oil.
Follow instructions for opening and replacing parts in refrigerant circuit.
If A/C system is opened for more than 24 hours:
Replace desiccant insert for A/C system
 Drawing off, evacuating and filling the A/C system are not included in the time value given for this
work operation
Carry out leak-testing with a leak tester device from the workshop equipment catalogue following the device
manufacturer's operating instructions.
2007 BMW 335i
If leaks not to be localized are already identified during evacuation, the A/C system must nevertheless be filled.
Then test for leaks with leak tester device.
NOTE: Refrigerant is heavier than air.
Therefore always conduct the leak test below the lines and components to be
tested.
Shield lines and components against strong blasts of air (wind, drawing off).
Tighten down loose lines, mark leaks.
Then draw off A/C system and seal off or repair leakage points.
Then refill A/C system and test for leaks.
64 50... SAFETY INSTRUCTIONS FOR HANDLING REFRIGERANT OIL
Refrigerant circuit is under high pressure! Work on the refrigerant circuit

may only be carried out by experts!
Draw off refrigerant without fail BEFORE all repair work on the refrigerant
circuit.
The refrigerant circuit is depressurized AFTER drawing off!
It is absolutely essential to read and observe the relevant operating

instructions for the A/C service unit used!

 Do not smoke!
 Observe country-specific safety regulations.
First aid measures:
 If swallowed: Do NOT induce vomiting, unless expressly instructed to do so by medical personnel. Do

not administer anything to an unconscious person through their mouth.
Consult a doctor immediately if larger quantities of this substance are swallowed. Loosen tight-fitting
items of clothing (e.g. collar, tie, belt or similar).
2007 BMW 335i
 Eye contact: Remove contact lenses if worn. In the event of eye contact, rinse eyes for at least 15 minutes
with plenty of water.
It is essential to use WARM WATER. Consult a doctor.
 Skin contact: In the event of skin contact, rinse immediately with plenty of water. Remove contaminated
clothes and shoes. Wash affected clothes before wearing again. Clean shoes thoroughly before reusing.
Call for a doctor.
 After inhalation: If inhaled, take the person affected outside into fresh air immediately and keep them
under supervision. Call for a doctor. If breathing difficulties are experienced, administer additional
oxygen. If the person affected stops breathing, administer the kiss of life.
Recycling
Catch and dispose of emerging refrigerant oil.
64 50... SAFETY INSTRUCTIONS FOR HANDLING TETRAFLUORETHANE REFRIGERANT

R134A
Refrigerant circuit is under high pressure! Work on the refrigerant circuit

may only be carried out by experts!
Draw off refrigerant without fail BEFORE all repair work on the refrigerant
circuit.
The refrigerant circuit is depressurized AFTER drawing off!
It is absolutely essential to read and observe the relevant operating

instructions for the A/C service unit used!

 Do not smoke!
 Observe country-specific safety regulations.
First aid measures:
 Eye contact: In the event of contact with the eyes, rinse immediately with plenty of running water and
consult an opthalmologist.
2007 BMW 335i
 Skin contact: In the event of contact with skin, remove affected clothing immediately and rinse with
plenty of water.
 After inhalation: If refrigerant vapors are inhaled in greater concentrations, remove the person affected to
an area of fresh air and keep them under supervision. Consult a doctor. If breathing problems are
experienced, breathe additional oxygen. If the person affected is breathing with difficulty or has stopped
breathing, incline the person's head at the neck and administer the kiss of life.
64 50 009 DRAWING OFF, EVACUATING AND FILLING A/C SYSTEM (R 134A)
WARNING: Refrigerant circuit is under high pressure!
Repair work may only be carried out on a DEPRESSURIZED refrigerant

circuit!
Only BMW-approved R134a refrigerant may be used (refer to sourcing

reference: Operating Fluids ).
NOTE: Draw off, evacuate and fill the A/C system in accordance with the operating
instructions of the relevant service station.
E60 only:
If necessary, to connect service station, use manufacturer's adapter for high-

pressure connection (red).
Instructions for drawing off A/C system:
To help separation of refrigerant and refrigerant oil, run engine at low speed (800-1200 RPM) and with A/C
system turned on for a few minutes.
The limits the entrainment of refrigerant oil while it is drawn off.
Drawn-off refrigerant oil must be changed and reintroduced via the service station.
If at the end of the drawing-off procedure the service station moisture indicator shows that the drawn-off
refrigerant is excessively moist, clean the refrigerant in accordance with the service station operating
2007 BMW 335i
instructions.
Recycling:
Dispose of drawn-off refrigerant oil as hazardous waste.
Instructions for evacuating off A/C system:
The evacuation procedure removes all traces of ambient air, water vapor and any other gases present from the
A/C system. This enables subsequent system filling with refrigerant.
A decrease in the vacuum level indicates a leak in the refrigerant circuit.
Instructions for filling A/C system:
Before filling with refrigerant, top up the refrigerant oil entrained during drawing off.
Follow instructions for opening and replacing parts in refrigerant circuit!
Depending on the type of component replaced on the A/C system, it may be necessary to top up the refrigerant
oil, even if no measurable losses have occurred during drawing off. Read and comply with the A/C system
manufacturer's notes in this regard and the operating instructions of the relevant service station.
Information on the required refrigerant fill quantity for the entire A/C system is contained on the rating plate (1)
in the engine compartment.
If necessary, refer to Technical Data for fill quantities.
Fig. 110: Rating Plate

Installation:
2007 BMW 335i
Reseal refrigerant filler necks on vehicle with sealing caps.
AC HOUSING/EVAPORATOR, SWITCHING ELEMENTS

64 51 001 CLEANING EVAPORATOR
 64 1 260
 64 1 270
WARNING: When handling cleaning agent, observe following protection measures:
Wear protective rubber gloves and protective goggles.
If cleaning agent comes into contact with eyes or skin, wash immediately
with lots of water.
IMPORTANT: To avoid dirtying vehicle interior:
 Close all air vents.

 Switch heating - A/C system to recirculated-air mode.
 Cover carpet in work area.
NOTE: For information on cleaning agent and rinsing again, refer to Service
Information .
For information on special tool, refer to Service Information Special Tools and
Equipment.
Recycling:
Carry out the cleaning operation in a suitable washing bay as the emerging cleaning agent escapes through the
drain openings in the transmission tunnel.
After completing cleaning, allow car to drip-dry for approx. 5 minutes.
 Remove rear underbody protection

 Remove heater/air conditioner fan
IMPORTANT: Use special tool 64 1 270 on right hand drive models.

2007 BMW 335i
Connect special tool 64 1 260 (spray lance) to spray gun (2). Insert spray lance 64 1 260 through opening (1)
into fresh air duct.
By moving spray lance (1) back and forth, spray a uniform amount of cleaning agent onto evaporator.
Fig. 111: Special Tools (64 1 260), Spray Gun, Spray Lance And Spraying Directions
Spray lance 64 1 260 shown on removed and cut-open heater/air conditioner:
 Spray lance 64 1 260 in upper end position (1)

 Spray lance 64 1 260 in lower end position (2)
By moving spray lance back and forth, spray a uniform amount of cleaning agent onto evaporator.
Fig. 112: Heater/Air Conditioner Upper End, Lower Positions And Spraying Directions
NOTE: Set heating - A/C system to footwell ventilation and fresh-air mode. Open
2007 BMW 335i
windows/doors.
Start car and run heating - A/C system at maximum fan power for approx. 5
minutes in order to dry evaporator.
In order to eliminate the last remnants of cleaning agent, repeat this procedure
shortly before handover to the customer.
64 52... INSTRUCTIONS FOR OPENING AND REPLACING PARTS IN REFRIGERANT CIRCUIT
See INSTRUCTIONS FOR OPENING AND REPLACING PARTS IN REFRIGERANT CIRCUIT.
64 51... LEAK-TESTING CONDENSER
Special tools Required
 00 9 030 (Wedge)
 64 5 121 (Connection hose with clamp)
 64 5 122 (Climate condenser test adapter)
 64 5 123 (Climate condenser seal plug)
Follow safety instructions for handling refrigerant.
Comply with the standard national safety instructions and precautions on

handling nitrogen.
Ensure that employees are advised of how to handle pressurized vessels

and nitrogen correctly (danger of asphyxiation). For this purpose, follow
the notes and instructions in the technical safety specifications available
from the gas supplier.
 Drain off air conditioner.

 Detach refrigerant lines from condenser
Tightening torque, see 64 53 6AZ in 64 53 REFRIGERANT LINES AND EXPANSION VALVE .
Special tool 64 5 122 and special tool 64 5 123 have different diameters (A, B) at
2007 BMW 335i
the seal plugs!
Ensure correct connection assignment on condenser.
Replace sealing rings (1) prior to each use.
Fig. 113: Identifying Special Tool 64 5 122, 64 5 123 & Sealing Rings
Fit and secure sealing adapter 64 5 123 to connection of low-pressure line.
Fit and secure test adapter 64 5 122 to connection of low-pressure line.
Tightening torque, see 64 53 6AZ in 64 53 REFRIGERANT LINES AND EXPANSION VALVE .
Fig. 114: Identifying Special Tool 64 5 122 & 64 5 123

Connect special tool 64 5 122 to special tool 64 5 121 .

2007 BMW 335i
Fig. 115: Identifying Special Tool 64 5 122 & 64 5 121

IMPORTANT: Risk of damage: Use only nitrogen pressure bottles with pressure reducers for
leak-testing.
Pressurize condenser to 10 bar slowly only. Excessively fast pressurization

and pressures in excess of 20 bar may cause damage to the condenser.
Connect nitrogen pressure bottle with pressure reducer to pressure gauge and then connect to special tool 64 5
121 (connecting hose).
NOTE:  Testing apparatus must be leakproof.

 Ambient temperature and temperature of vehicle must not change during
the test procedure.
 Do not move the vehicle during this period
Apply test pressure of 10 bar slowly and close nitrogen pressure bottle.
Check leak-tightness of testing apparatus and of connection to refrigerant line.
Set test pressure of 10 bar is only permitted to drop by 2 bar to 8.5 bar over a test period of 1.5 hours.
If the pressure loss is greater than 1.5 bar, this indicates that there is a leak in the condenser unit.
WARNING: After leak-testing, unscrew special tool 64 5 121 slowly from special tool
64 5 122 to reduce pressure.
After leak-testing:
 Replace all sealing rings and moisten with refrigerant oil

 Assemble A/C system
 Evacuate and fill A/C system
2007 BMW 335i
64 51 520 REMOVING AND INSTALLING OR REPLACING EXPANSION VALVE
A/C system
work operation
Release screws (1, 2), disconnect refrigerant lines and lay to one side.
Installation:
Replace all sealing rings and moisten with refrigerant oil.
For tightening torque refer to 64 53 2AZ in 64 53 REFRIGERANT LINES AND EXPANSION VALVE .
Fig. 116: Refrigerant Lines Screws

2007 BMW 335i
Release screws (1) and remove expansion valve (2).
Fig. 117: Expansion Valve And Screws

Installation:
Place expansion valve (1) exactly on refrigerant lines (2) and (3).
Fit screws of expansion valve (1) and make sure retainer (4) is correctly positioned.
Fig. 118: Expansion Valve, Refrigerant Lines And Retainer

After installation:
2007 BMW 335i
64 51 580 LEAK-TESTING EVAPORATOR
 64 5 104
 64 5 107
 Remove expansion valve
Screw down special tool 64 5 107 with retaining clip (1).
Fig. 119: Special Tool (64 5 107) And Retaining Clip

Connect special tool 64 5 104 to special tool 64 5 107.

2007 BMW 335i

IMPORTANT: Risk of damage: Use only nitrogen pressure bottles with pressure reducers for
leak-testing.
Pressurize evaporator to 15 bar slowly only. Excessively fast pressurization

and pressures in excess of 20 bar may cause damage to the evaporator.
Connect nitrogen pressure bottle with pressure reducer to pressure gauge and then connect to special tool 64 5
104 (connecting hose).
NOTE:  Testing apparatus must be leakproof.

 Ambient temperature and temperature of vehicle must not change during
the test procedure.
 Do not move the vehicle during this period
Slowly apply test pressure of 15 bar and close nitrogen pressure bottle.
Check leak-tightness of testing apparatus and of connection to refrigerant line.
Set test pressure of 15 bar is only permitted to drop by 2 bar to 13 bar over a test period of 2 hours.
If the pressure loss is greater than 2 bar, this indicates that there is a leak in the evaporator unit.
After installation:
 Replace all sealing rings and moisten with refrigerant oil

64 51 591 REMOVING AND INSTALLING/REPLACING EVAPORATOR

2007 BMW 335i
 Remove Heater/Air Conditioner.
Carefully pull rubber grommet (1) and foam seal (2) over pipes (3) and (4).
NOTE: If necessary, replace rubber grommet (1) and/or foam seal (2).
Release screws (5).
Fig. 121: Identifying Evaporator Pipes, Retaining Screws, Rubber Grommet And Foam Seal
Carefully remove seal (2) and all remnants.
Installation:
Replace seal (2).
Turn temperature sensor for cold-air distributor (3) in direction of arrow and detach in upwards direction.
Expose connecting cable (4) of temperature sensor for cold-air distributor (3) towards rear of heater/air
conditioner (5).
2007 BMW 335i
Fig. 122: Identifying Temperature Sensor, Cable, Seal, Plug Connection And Heater/Air Conditioner
Release screws (1).
Remove upper housing (2) of heater/air conditioner in direction of arrow.
Installation:
Make sure upper housing (2) is correctly seated on heater/air conditioner.
Fig. 123: Identifying Evaporator Upper Housing And Retaining Screws

Pull evaporator (1) in direction of arrow out of lower housing (2) of heater/air conditioner.
Installation:
Make sure evaporator (1) is correctly seated in lower housing (2) of heater/air conditioner.
2007 BMW 335i
Fig. 124: Identifying Evaporator And Heater/Air Conditioner Housing

IMPORTANT: Do not bend radiator fins.
If necessary, clean or straighten radiator fins with slat comb.
COMPRESSOR
64 52... INSTRUCTIONS FOR COMPRESSOR REPLACEMENT
IMPORTANT: Compressors with plastic belt pulleys:
 Avoid impacts/knocks to plastic belt pulley (caused by tools, contact with

base).
 Return faulty compressors in their original packaging only.
IMPORTANT: When starting up a new compressor for the first time, it is absolutely essential
to carry out the following breaking-in procedure:
 Switch on A/C system

 Set all air vents in instrument cluster to "OPEN"
 Start engine and let it stabilize at idle speed
 Set blower output to min. 75 % of max. blower output
 Switch on A/C system and run for at least 2 minutes at idle speed (risk of
damage at higher speed!)
When evacuating the air-conditioning system, refrigerant oil is also extracted and collected in the oil separator
of the service station.
After evacuation, the refrigerant must be filtered in the service station as the oil separator could still contain a
2007 BMW 335i
liquid refrigerant/oil mixture. The filtering process gasifies the refrigerant completely and only the previously
bound refrigerant oil remains in the oil separator. Measure and note down this quantity of refrigerant oil, refer to
Evacuating A/C system.
Fig. 125: Evacuating A/C Refrigerant Oil From A/C System

Transfer the refrigerant oil remaining in the previous compressor via the filler plug completely into a measuring
container.
Fig. 126: Draining Refrigerant Compressor Oil Into Measuring Container

Measure the amount of refrigerant oil collected from the previous compressor.
2007 BMW 335i
Fig. 127: Measuring Amount Of Refrigerant Oil

The new compressor is filled at the factory with refrigerant oil. Open filler plug and pour entire contents of
compressor into a clean container.
Installation:
Replace sealing ring and moisten with refrigerant oil.
Observe tightening torque, refer to 64 52 2AZ in 64 52 A/C COMPRESSOR .
Fig. 128: Draining Refrigerant Compressor Oil Into Clean Container

From the new compressor, pour the same amount of refrigerant oil (as drained from the previous compressor) +
10 g extra into a clean measuring container and pour again into the new compressor.
Remaining refrigerant oil can be poured into service station tank, refer to Evacuating A/C system.
2007 BMW 335i
Otherwise the excess refrigerant oil must be disposed of correctly.
On account of its hygroscopic properties, refrigerant oil must not be stored in open containers.
Fig. 129: Pouring Same Amount Of Refrigerant Oil Into Clean Measuring Container
The refrigerant oil drawn off from the oil separator of the service station and from the previous compressor
must not be reused and must be correctly disposed of.
Fig. 130: Draining Refrigerant Oil From Oil Separator

After installing the new compressor, it is essential before filling the A/C system to pour the same amount of the
previously drawn off refrigerant oil into the system again, refer to Evacuating A/C system.
2007 BMW 335i
Fig. 131: Filling Refrigerant Oil Into A/C System

Installation:
If A/C system is opened for more than 24 hours: Replace drier bottle/drier insert.
WARNING:  Avoid contact with refrigerant and refrigerant oil

 Follow safety instructions for handling R134a refrigerant
 Follow safety instructions for handling refrigerant oil
CAUTION:  Always use new O-rings each time A/C connections are opened
 Moisten O-rings with refrigerant oil prior to fitting
 Seal all parts to be returned at openings to prevent ingress of
moisture or foreign bodies
I. Opening refrigerant circuit without part replacement, as preliminary work to further work
(e.g. engine removal):
Work sequence:
 Draw off A/C system, then determine drawn-off refrigerant oil quantity
 Carry out main work
 Replace removed refrigerant oil with new refrigerant oil
 Evacuate and fill Draw off
II. Part replacement and part replacement on account of insidious leak

2007 BMW 335i
(minor leak, e.g. hairline crack)
Work sequence:
 Carry out part replacement
 Additionally replenish new refrigerant oil in accordance with replaced parts:
 Compressor: refer to Notes on replacing compressor
 Evaporator: 10 ml
 Condenser: 10 ml
 Desiccant insert / desiccant bottle: 30 ml
 Each replaced refrigerant line: 10 ml
 Condenser with integrated dryer: 30 ml
 Safety pressure switch and seals: no additional refrigerant oil
III. Part replacement on account of sudden leak
(major leak, e.g. pipe break due to accident)
Work sequence:
 Carry out part replacement
 Additionally replenish 25 ml new refrigerant oil and new refrigerant oil in accordance with
replaced parts:
 Compressor: refer to Notes on replacing compressor
 Evaporator: 10 ml
 Condenser: 10 ml
 Desiccant insert / desiccant bottle: 30 ml
 Each replaced refrigerant line: 10 ml
 Condenser with integrated dryer: 30 ml
 Safety pressure switch and seals: no additional refrigerant oil
64 52 521 REPLACING A/C SYSTEM COMPRESSOR (N51)

2007 BMW 335i
Follow safety instructions for Handling Refrigerant R 134A.
Follow safety instructions for Handling Refrigerant Oil.
IMPORTANT: No steel screws/bolts may be used due to the threat of electrochemical

corrosion.
Aluminum screws/bolts must be replaced each time they are released.
damage).
Restart engine only when air conditioning system has been correctly filled.
Read and comply with notes on replacing compressor.
If air conditioning system is opened for more than 24 hours:
Replace Desiccant Insert For A/C System
 Drawing Off, Evacuating And Filling The A/C System are not included in the time value given for this
work operation.
 Release expansion tank and place to one side.
 Remove fan cowl. See 17 11 035 REMOVING AND INSTALLING/REPLACING FAN COWL
WITH ELECTRIC FAN (N52/N52K/N53) .
 Remove air conditioning compressor drive belt. See 11 28 010 REPLACING ALTERNATOR DRIVE
BELT (N51) .
 Remove coolant thermostat. See 11 53 000 REMOVING AND INSTALLING/REPLACING
COOLANT THERMOSTAT (N51) .
Release screws (1, 2) and remove refrigerant lines. Tightening torque, see 64 52 1AZ in 64 52 A/C
COMPRESSOR . Installation: Replace sealing rings. Use special tool 00 9 030 to mount sealing rings without
2007 BMW 335i
damaging them. Disconnect plug connection (3).
Fig. 132: Removing And Installing Refrigerant Lines

IMPORTANT: Close openings or line to compressor with special tool 32 1 270, to avoid media
leak and dirt contamination.
NOTE: Secure compressor (3) against falling out.
Release screw (1). Unfasten screws (2). Tightening torque, see 64 52 3AZ in 64 52 A/C COMPRESSOR .
Remove compressor towards front.
Fig. 133: Removing Compressor

After installation: Evacuate and fill A/C system. Fill and vent cooling system and check for leaks. See 17 00
039 VENTING COOLING SYSTEM AND CHECKING FOR WATER LEAKS (N52/N52K/N51/N53) .
64 52 521 REPLACING A/C SYSTEM COMPRESSOR (N52)

2007 BMW 335i
Follow safety instructions for handling R134a refrigerant
Follow safety instructions for handling refrigerant oil

corrosion.
damage ).
Replace desiccant insert for A/C system
work operation
 Release expansion tank and place to one side
 Remove fan cowl
 Remove A/C compressor drive belt
 Remove coolant thermostat
Release screws (1, 2) and remove refrigerant lines.

2007 BMW 335i
Installation:
For tightening torque refer to 64 52 1AZ in 64 52 A/C COMPRESSOR .
Fig. 134: Screws And Plug Connection

NOTE: Secure compressor (3) against falling out.
Release screw (1).
For tightening torque refer to 64 52 3AZ in 64 52 A/C COMPRESSOR .
Remove compressor towards front.
Fig. 135: Screws And Compressor

2007 BMW 335i
After installation:

CONDENSER AND DRYER WITH LINES

64 53...INSTRUCTIONS FOR DESICCANT INSERT REPLACEMENT
A desiccant insert that is in a correctly functioning, sealed heating and air conditioning system does not have to
be changed at regular service-inspection intervals.
However, the dryer flask or desiccant insert must absolutely be replaced in the event of:
 contamination of the refrigerant with debris (e.g. when the compressor is clamped).
 With depressurized and/or completely drained refrigerant circuit.
 With a refrigerant circuit, which was closed using special tool 32 1 270 but remains open for more than
24 hours.
The desiccant insert cannot be replaced in the following vehicles:
 1-Series E8x, 3-Series E9x from 12/2008

 E84, E89
 1-Series F2x, 3-Series F3x
In these vehicles, the condenser for the heating and air conditioning system must be replaced.
See INSTRUCTIONS FOR OPENING AND REPLACING PARTS IN REFRIGERANT CIRCUIT.
64 53...INSTRUCTIONS FOR REPLACEMENT OF AIR CONDITIONING CAPACITORS AND

RADIATOR/COOLERS
IMPORTANT: Even when they are correctly installed or due to normal driving, coolers (oil
cooler, radiator, charge air cooler) or air conditioning capacitors may show
slight impressions or deformations on their discs (picture).
This is not damage.
Radiators, cooler or capacitors are not to be replaced in this case.
NOTE: The deformations shown in illustration "1" (see Fig. 136) can be bent back with
2007 BMW 335i
a standard fin comb.
Damage to lines carrying media or on the flat pipe require replacement of the radiator/ or air conditioning
condenser. Examples of such damage are shown in illustrations "2", "3", "4", "5", and "6" (see Fig. 136).
Fig. 136: Identifying Damage And Deformations

64 51... LEAK-TESTING CONDENSER
See LEAK-TESTING CONDENSER.
64 53... OVERVIEW OF A/C CIRCUIT COMPONENTS

2007 BMW 335i
Fig. 137: Overview Of A/C Circuit Components

64 53... NOTES ON REPLACING DRIER BOTTLE OR DRIER INSERT
The drier bottle or drier insert does not have to be replaced at regular service intervals in a functioning,
leakproof A/C system.
However, the drier bottle or drier insert must be replaced without fail in the event of:
 fouling of the refrigerant by filings/shavings (e.g. when the compressor is clamped)

 a leaking A/C system or loss of refrigerant
 the refrigerant circuit being opened for a period exceeding 24 hours, e.g. during repair work.
64 53... REPLACING VALVE INSERT FOR REFRIGERANT LINE

2007 BMW 335i
Follow instructions for opening and replacing parts in refrigerant circuit
If A/C system is opened for more than 24 hours: Replace desiccant insert for
A/C system
work operation
Twist valve insert out of filler neck (2) with remover (1).
Installation:
Screw in valve insert hand-tight only.
Fig. 138: Remover And Filler Neck

After installation:
2007 BMW 335i

 Check leak-tightness of valve insert with soapy solution
In event of leakage:
 Evacuate A/C system

 Check sealing faces on line and valve insert for damage, replace line or valve insert if necessary
 If necessary, carry out leak detection
64 53 515 REPLACING DESICCANT INSERT FOR A/C SYSTEM
Follow safety instructions for handling refrigerant oil
Replacing drier insert for A/C system
work operation
 Remove condenser
If necessary, pierce sticker over sealing cap (1).
Remove cap (1) from condenser (2).
Installation:
2007 BMW 335i
Fig. 139: Sealing Cap And Condenser

Remove Seeger circlip ring (1) with suitable pliers.
Fig. 140: Seeger Circlip Ring

With assistance of a screwed-in screw (1), withdraw desiccant insert (2) from condenser (3).
2007 BMW 335i
Fig. 141: Desiccant Insert, Condenser, Screwed-In Screw And Removal Direction
After installation:

64 53 520 REPLACING SAFETY PRESSURE SWITCH
Follow safety instructions for handling refrigerant oil handling refrigerant

oil.
A/C system

2007 BMW 335i
work operation
Release screws (1) and bend thermal insulation (2) to one side.
Fig. 142: Screws And Insulation

Disconnect plug connection (1) and release safety pressure switch (2).
Fig. 143: Plug Connection And Safety Pressure Switch

After installation:
64 53 550 REMOVING AND INSTALLING OR REPLACING CONDENSER (WITH DESICCANT

2007 BMW 335i
INSERT) FOR HEATING AND AIR CONDITIONING SYSTEM
Follow safety instructions for handling refrigerant oil handling refrigerant

oil.
If A/C system is opened for more than 24 hours: Replacing drier insert for A/C
system
work operation
 Remove radiator
Release screws (1).
Disconnect suction and pressure lines and lay to one side.
Installation:
For tightening torque refer to 64 53 1AZ 64 53 REFRIGERANT LINES AND EXPANSION VALVE .
2007 BMW 335i
Fig. 144: Screws

Release screw (1).
Lever out retainer (2).
Remove condenser (3) towards rear.
Installation:
Make sure retaining clips are correctly seated in area (4).
Fig. 145: Screws, Retainer, Seated Area And Condenser

Installation:
Make sure condenser (1) is securely seated in area (2).

2007 BMW 335i
Fig. 146: Condenser And Seated Area

After installation:

2007 BMW 335i
ACCESSORIES AND EQUIPMENT Instruments - Repair Instructions
Instruments - Repair Instructions
INSTRUMENT CLUSTER
62 11 280 REMOVING AND INSTALLING (REPLACING) INSTRUMENT CLUSTER
protection) .
NOTE: Extend steering wheel completely and lower.
Release bolts (1).
Tightening torque: 1.5 Nm.
Fold back instrument cluster (2) in direction of arrow and pull back slightly.
Disconnect associated plug connection.
If necessary, feed out/unclip associated wiring harness.
Remove instrument cluster (2).
Fig. 1: Identifying Instrument Cluster And Mounting Bolts

Replacement:
 Carry out vehicle programming/coding

 Check values for Condition Based Service (CBS) , correct if necessary
2007 BMW 335i
ACCESSORIES AND EQUIPMENT Lights - Repair Instructions
Lights - Repair Instructions
LAMP SETTINGS
63 10... TEST REQUIREMENTS FOR HEADLIGHT VERTICAL AIM ADJUSTMENT
 Car parked on level ground.

 Replace faulty glass and mirrors and blackened light bulbs.
 Check tire pressure and correct if necessary.
 Apply load equivalent to one person on driver's seat (approx. 75 kg).
 Vehicle with full fuel tank or appropriate additional weight in luggage compartment.
 Correct adjustment of headlights in relation to engine hood (gap dimensions).
 Manual headlight vertical aim control: Turn handwheel to 0 position.
 Automatic headlight vertical aim control: Wait approx. 30 seconds after switching on lights.
 Version with xenon headlights: Wait 80 seconds after switching on lights. During this time, do not move
the vehicle and avoid vibrations.
 Align headlight aimer with vehicle longitudinal axis and parallel to parking surface. Set marking line (M)
on aimer to distance (e). Scale graduations on aimer are equal to a gradient in cm at a distance of 10
meters.
2007 BMW 335i
Fig. 1: Identifying Headlight Aimer Adjustment Pattern

Light/dark limit of headlights in headlight aimer
e Adjustment dimension, headlights:

 as per type plate on headlight housing in % (e.g.: 1.0 % = 10 cm / 10 m = 10 on headlight aimer).
Adjustment dimension, fog lights:
 all vehicles 2.0 % = 20 cm / 10 m = 20 on headlight aimer.

H Height of center of headlight above parking surface.
h H - e = height of marking line above parking surface
+ Central mark = center point of high-beam headlight.
M Marking line of headlamp aimer
S Parking surface of vehicle and headlight aimer
Adjustment dimension (e) is only valid for EUR. Observe differing national regulations.
63 10 004 ADJUSTING HEADLIGHTS
NOTE: Comply with Test Preconditions For Headlight Adjustment.
Adjust headlights at adjusting screws (1) and (2).
A definite allocation of adjusting screws is not possible.
1. Adjustment screw primarily for vertical adjustment

2. Adjustment screw primarily for lateral adjustment
Fig. 2: Identifying Vertical And Lateral Adjusting Screws

2007 BMW 335i
63 10 014 ADJUSTING FOG LAMPS
NOTE: Comply with Test Preconditions For Headlight Adjustment.
Carry out height adjustment of fog lamp (1) at adjusting screw (2).
Fig. 3: Identifying Fog Lamp And Screw

FRONT LIGHTS
63 11... INSTALLING HEADLIGHT REPAIR KIT
 Remove headlight. See XENON HEADLIGHT or ADAPTIVE HEADLIGHT.
NOTE: Damaged retaining tabs (1) can be replaced with the repair kit.
Replacement of headlight is not required !
Remove damaged retaining tabs (1) up to line marked with arrows.
Mount retaining tab from repair kit (3) as shown and tighten screw (2).
2007 BMW 335i
Fig. 4: Identifying Retaining Tabs And Screw

After installation:
 Adjust headlights. See ADJUSTING HEADLIGHTS.
63 11 741 REPLACE LEFT DAYTIME DRIVING LIGHTS CONTROL UNIT
 Remove LEFT HEADLIGHT
Release screws (1).
Lift control unit (2) from headlight (3).
Unlock plug connections behind and disconnect.
Installation note:
Ensure that sealing cup is correctly seated.
Ensure that daytime driving lights control unit (2) is correctly seated.
2007 BMW 335i
Fig. 5: Identifying Control Unit And Screws

63 11 731 REPLACING LEFT DAYTIME LIGHT LED MODULES
Follow instructions for HANDLING LIGHT BULBS (EXTERIOR LIGHTS).
 Remove left headlight
Release screws (1).
Carefully lift LED module (2) slightly upwards.
Fig. 6: Identifying LED Module And Screws


2007 BMW 335i
Remove LED module (2).
Installation note:
Always replace LED modules (2) as a pair.
Replace seal for LED module (2).
Make sure LED module (2) is correctly seated.
Note BULB TYPE .
Fig. 7: Identifying LED Module And Connector

HEADLIGHTS
63 12... HEADLIGHT FOGGING FAULT PATTERN
NOTE: Certain weather conditions can lead to fogging on the inside of the headlight
lens.
This is not necessarily a fault that requires replacement of the headlight.
(A): Permissible fogging. Headlight does not need to be replaced.
(B): Impermissible fogging. Replace the headlight.

2007 BMW 335i
Fig. 8: Identifying Permissible And Impermissible Fogging

63 12 010 REMOVING AND INSTALLING/REPLACING LEFT HEADLIGHT (XENON

HEADLIGHT)
Therefore, before removing, disconnect all components from the power
supply (lighting system and ignition off).
bulb) may only be carried out by specialist personnel.
Follow instructions for handling light bulbs(Exterior Lights).
Protection).
 Remove Bumper Trim
Unlock catches (1) in direction of arrow and remove high-pressure nozzle (2) towards rear out of headlight arm
2007 BMW 335i
(3).
Fig. 9: Identifying Catches, High-Pressure Nozzle And Headlight Arm

Release screw (1) on headlight arm (2) (from wheel arch side).
Fig. 10: Identifying Screw And Headlight Arm

Release screws (1). For tightening torque refer to 63 12 3AZ in 63 12 HEADLIGHTS .
Installation:
 Observe Gap Dimensions

If necessary, unclip electric lead (2) from headlight arm.
Pull out headlight (3) slightly and unlock and disconnect associated plug connection.
2007 BMW 335i
Remove headlight (3) towards front.
Fig. 11: Identifying Headlight, Screws, Wiring Harness And Removal Direction
Replacement:
 Release screws (1) (for tightening torque refer to 63 12 2AZ in 63 12 HEADLIGHTS ) and remove
headlight arm (2) from headlight.
 Remove Ignition Unit With Bulb For Xenon Headlight
 Remove Control Unit For Xenon Headlights
 If necessary, remove Bulbs.
Fig. 12: Identifying Screws And Headlight Arm

63 12 012 REMOVING AND INSTALLING RIGHT HEADLIGHT (XENON HEADLIGHT)

2007 BMW 335i
Removing and installing left headlight
63 12 015 REMOVING AND INSTALLING/REPLACING LEFT HEADLIGHT (ADAPTIVE

HEADLIGHT)
Follow instructions for Handling Light Bulbs (Exterior Lights).
Protection).
Unlock catches (1) in direction of arrow and remove high-pressure nozzle (2) towards rear out of headlight arm
(3).
Fig. 13: Identifying High-Pressure Nozzle, Headlight Arm, Catches And Removal Direction
Release screw (1) on headlight arm (2) (from wheel arch side).
For tightening torque refer to 63 12 1AZ in 63 12 HEADLIGHTS .

2007 BMW 335i
Fig. 14: Identifying Screw And Headlight Arm

Installation:
 Observe Gap Dimensions

If necessary, unclip electric lead (2) from headlight arm.
Pull out headlight (3) slightly and unlock and disconnect associated plug connection.
Remove headlight (3) towards front.
Fig. 15: Identifying Headlight, Screws, Electric Lead And Removal Direction
Replacement:
2007 BMW 335i
 Release screws (1) and remove headlight arm (2) from headlight.
 Remove Ignition Unit With Bulb For Xenon Headlight
 Remove Control Unit For Xenon Headlights
 Remove Drive Unit For Adaptive Headlight
 If necessary, remove Bulbs.
Fig. 16: Identifying Screws And Headlight Arm

63 12 017 REMOVING AND INSTALLING/REPLACING RIGHT HEADLIGHT (ADAPTIVE

HEADLIGHT)
Removing And Installing Left Headlight
6716011 REMOVING AND INSTALLING/REPLACING LEFT VERTICAL AIM ADJUSTER

(XENON HEADLIGHT)
Therefore disconnect all components from voltage supply before removal.
 Remove WHEEL ARCH COVER at front
NOTE: For purposes of clarity, following illustrations show headlight removed.
Release catches (1) and remove protective cap (2).

2007 BMW 335i
Fig. 17: Identifying Catches And Protective Cap

Turn vertical aim adjuster (2) to left and feed out of fixture.
Fig. 18: Identifying Plug Connection And Vertical Aim Adjuster

Installation:
Slide headlight insert (1) upwards in direction of arrow.

2007 BMW 335i
Fig. 19: Sliding Headlight Insert Upwards In Direction Of Arrow

Feed ball head of vertical aim adjuster (1) into mounting (2).
Fig. 20: Feeding Ball Head Of Vertical Aim Adjuster Into Mounting
After installation
 ADJUST HEADLIGHTS
67 16 016 REMOVING AND INSTALLING/REPLACING RIGHT HEADLIGHT VERTICAL AIM

ADJUSTER
Operation is identical to: LEFT VERTICAL AIM ADJUSTER
63 12 860 REPLACING CONTROL UNIT FOR LEFT XENON HEADLIGHT
2007 BMW 335i

Protection).
 Remove Front Left Wheel Arch Trim
NOTE: Headlight removed for purposes of clarity.
Lift control unit (2) off headlight.
Fig. 21: Identifying Headlight Screws And Control Unit

Installation:
Make sure sealing sleeve (3) is correctly seated.

2007 BMW 335i
Fig. 22: Identifying Control Unit, Sleeve And Plug Connection

63 12 861 REPLACING CONTROL UNIT FOR RIGHT XENON HEADLIGHT
Protection).
N52:
 Remove Front Right Wheel Arch Trim
N54 / S65:
 Remove right headlight
Lift control unit (2) off headlight.

2007 BMW 335i
Fig. 23: Identifying Headlight Screws And Control Unit

Installation:
Make sure sealing sleeve (3) is correctly seated.
Fig. 24: Identifying Control Unit, Sleeve And Plug Connection

63 12 870 REPLACING IGNITION UNIT FOR LEFT XENON HEADLIGHT (WITH XENON BULB)
2007 BMW 335i
Follow instructions for handling light bulbs (Exterior Lights).
IMPORTANT: Ignition unit and xenon bulb are viewed as a single component and must not be
separated.
 Remove Front Left Wheel Arch Trim
Release screws (1) and remove cover (2) from headlight.
Installation:
Make sure cover (1) is correctly seated on headlight (2) (otherwise headlight subject to leaks).
Fig. 25: Identifying Headlight Cover And Screws

Unlock spring wire clips (2).
Remove ignition unit for xenon headlight (3) from headlight.
Installation:
Make sure ignition unit (3) is exactly seated in headlight.

2007 BMW 335i
Fig. 26: Identifying Ignition Unit, Plug Connection And Spring Wire Clips
63 12 871 REPLACING IGNITION UNIT FOR RIGHT XENON HEADLIGHT (WITH XENON BULB)
Follow instructions for handling light bulbs (Exterior Lights).
IMPORTANT: Ignition unit and xenon bulb are viewed as a single component and must not be
separated!
 Remove Front Right Wheel Arch Trim
Release screws (1) and remove cover (2) from headlight.
Installation:
Make sure cover (1) is correctly seated on headlight (2) (otherwise headlight subject to leaks).
2007 BMW 335i
Fig. 27: Identifying Headlight Cover And Screws

Unlock spring wire clips (2).
Remove ignition unit for xenon headlight (3) from headlight.
Installation:
Make sure ignition unit (3) is exactly seated in headlight.
Fig. 28: Identifying Ignition Unit, Plug Connection And Spring Wire Clips
63 12 895 REPLACING ELECTRONICS BOX/CONTROL UNIT FOR LEFT ADAPTIVE

HEADLIGHT
2007 BMW 335i
Work on the entire xenon lighting system (ignition unit, control unit and
Protection). .
 Remove Left Headlight
Release screws (1).
Remove drive for adaptive headlight (2) in direction of arrow from headlight.
Fig. 29: Identifying Adaptive Headlight And Screws

Installation:
Fit drive for adaptive headlight (1) exactly on headlight.
Make sure pin housing (2) is correctly seated in plug housing (3).
2007 BMW 335i
Fig. 30: Identifying Adaptive Headlight, Plug Housing And Pin Housing
Carry out VEHICLE PROGRAMMING AND CODING
63 12 896 REPLACING ELECTRONICS BOX/CONTROL UNIT RIGHT ADAPTIVE HEADLIGHT
Replacing Drive For Left Adaptive Headlight
63 12... REPLACING DRIVE/ELECTRONICS BOX FOR LEFT ADAPTIVE HEADLIGHT (FROM

SERIES STATUS 09/2008)
PROTECTION) .
 Remove FRONT LEFT WHEEL ARCH COVER
Release screws (1).
Remove drive for adaptive headlight (2) from headlight (3).

2007 BMW 335i
Fig. 31: Identifying Screws, Headlight And Adaptive Headlight

IMPORTANT: Drive for adaptive headlight (1) is engaged in housing (3).
Installation:
Fit drive for adaptive headlight (1) exactly on headlight.
Make sure pin housing (2) is correctly seated.
Fig. 32: Identifying Adaptive Headlight And Pin Housing

2007 BMW 335i
Carry out VEHICLE PROGRAMMING AND CODING .
TURN SIGNAL INDICATOR LIGHTS

63 13 200 REMOVING AND INSTALLING/REPLACING FRONT LEFT OR RIGHT AUXILIARY
TURN SIGNAL LAMP
WARNING: Follow instructions for handling light bulbs (Exterior Lights).
Slide from auxiliary turn signal lamp (1) towards rear and fold in direction of arrow out of front side wall (2).
Remove front auxiliary turn signal lamp (1).
Replacement:
If necessary, convert Bulbs.
Note Bulb Type.
Fig. 33: Identifying Front Auxiliary Turn Signal Lamp, Front Side Wall And Folding Direction
63 13 080 REMOVING AND INSTALLING/REPLACING LEFT DIRECTION INDICATOR INSERT

FROM SERIES STATUS 09/2008
Release screws (1).

2007 BMW 335i
Remove direction indicator insert (2) from headlight (3).
Fig. 34: Identifying Screws, Direction Indicator Insert And Headlight

Remove direction indicator insert (2) from headlight (3).
Fig. 35: Identifying Plug Connection, Direction Indicator Insert And Headlight
63 11 701 REPLACING LEFT TURN INDICATOR (LED)
Release screw (1).

2007 BMW 335i

Release screw (1) and remove holder (2) from headlight (3).
Installation note:
Make sure holders (2) are correctly seated.
Fig. 37: Identifying Holder And Screw

Release screws (1).
Carefully remove turn indicator (2) from headlight (3) towards top.
2007 BMW 335i
Fig. 38: Identifying Turn Indicator And Screws

Remove turn indicator (2).
Installation note:
Make sure turn indicator (LED) (2) is correctly seated.
Make sure sealing cup is correctly seated.
Fig. 39: Identifying Turn Indicator Connector

63 11 721 REPLACING LEFT TURN INDICATOR (LED) CONTROL UNIT

2007 BMW 335i
Release screws (1).
Carefully lift control unit (2) for headlight (3) slightly upwards.
Fig. 40: Identifying Control Unit And Screws

Installation note:
Make sure control unit (2) is seated correctly.
Fig. 41: Identifying Control Unit Connectors

CLEARANCE AND SIDE MARKER LAMPS

2007 BMW 335i
63 14 060 REMOVING AND INSTALLING/REPLACING FRONT LEFT OR RIGHT SIDE MARKER
 00 9 318
 Remove front Wheel Arch Cover
NOTE: Minimum object temperature of side marker and bumper trim > or = 18°C.
If this temperature is not achieved, the components must be preheated.
Removing side marker:
Carefully heat side marker (1) in area (A) with hot air blower and detach with special tool 00 9 318 from
bumper trim (2).
NOTE: Side marker (1) cannot be reused.
Fig. 42: Identifying Side Marker, Area And Bumper Trim

Cleaning bumper trim:
For cleaning, use a fluff-free disposable cloth or a clean cleaning cloth.
Clean adhesive area of bumper trim with spirit.
Air drying time at least 1 minute.
Do not grip bonding surface.

2007 BMW 335i
Fitting side marker:
Pull off liner* (1) and gently press side marker (2) onto bumper trim.
Check position and if necessary realign.
Minimum application pressure is achieved by applying firm thumb pressure in stages over the entire joining
surface (hold time approx. 1 second).
Firm thumb pressure approx. 35 N/cm2 .
* Liner is the protective film on a new side marker.
Fig. 43: Identifying Side Marker And Liner

FOG LIGHTS, AUXILIARY LIGHTS

63 17 070 REMOVING AND INSTALLING/REPLACING LEFT FRONT FOG LAMP
NOTE: The time value of this job does not include adjustment of the Fog Lamps!
Release screws (2).
Remove fog lamp (3) towards front from bumper trim.

2007 BMW 335i
Fig. 44: Identifying Plug Connection And Lamp Screws

Replacement:
Adjust Front Fog Lamps.
63 17 070 REMOVING AND INSTALLING/REPLACING RIGHT FRONT FOG LAMP
NOTE: The time value of this job does not include adjustment of the Fog Lamps!
N52, N53:
N54:
Release screws (2).
Remove fog lamp (3) towards front from bumper trim.

2007 BMW 335i
Fig. 45: Identifying Plug Connection, Lamp And Screws

Replacement:
Adjust Front Fog Lamps.
REAR LIGHT CLUSTER

63 21 055 REPLACING A SOCKET HOUSING FOR LEFT OR RIGHT REAR LIGHT (SIDE PANEL)
(COUPE)
WARNING: Follow instructions for handling light bulbs (Exterior Lights)
Fig. 46: Identifying Cover, Luggage Compartment Wheel Arch Trim And Removal Direction
2007 BMW 335i
Unlock locking clip (2) in direction of arrow and remove socket housing (3) from rear light.
NOTE: Convert bulbs, replace if necessary.
Note Type Of Bulb.
Fig. 47: Identifying Socket Housing, Locking Clip, Plug Connection And Removal Direction
63 21 055 REPLACING A SOCKET HOUSING FOR LEFT OR RIGHT REAR LIGHT (SIDE PANEL)
(CONVERTIBLE)
WARNING: Follow instructions for handling light bulbs (exterior lights)
Release rotary clip (1) and remove cover (2).

2007 BMW 335i
Turn socket housing (1) and pull out of rear light.
Note bulb type: 3 LEDs.
Fig. 49: Turning Socket Housing

63 21 057 REPLACING A SOCKET HOUSING FOR LEFT OR RIGHT REAR LIGHT (REAR LID)
(COUPE)
 Partially remove TRIM PANEL FOR REAR LID
WARNING: Follow instructions for HANDLING LIGHT BULBS (EXTERIOR LIGHTS).
Unlock locking clip (2) in direction of arrow and remove socket housing for rear light (3) from rear light (4).
Note BULB TYPE .

2007 BMW 335i
Fig. 50: Identifying Plug Connection, Locking Clip, Socket Housing And Rear Light
63 21 057 REPLACING A SOCKET HOUSING FOR LEFT OR RIGHT REAR LIGHT (REAR LID)
(CONVERTIBLE)
 Partially remove trim panel for rear lid
Note bulb type: 3 LEDs.

63 21 070 REMOVING AND INSTALLING/REPLACING BULB HOLDER IN LEFT (OR RIGHT)

REAR LIGHT (CONVERTIBLE)
2007 BMW 335i
 Remove rear light
Release screws (1).
Remove bulb holder (3).
Replacement:
Convert bulbs, replace if necessary.
Note type of bulb: 3 LEDs.
Fig. 52: Identifying Bulb Holder, Connectors, And Screws

63 21 101 REPLACING SEALING FRAME FOR LEFT OR RIGHT REAR LIGHT (ON SIDE PANEL)
(COUPE)
 Remove Rear Light
Detach seal for rear light (1) completely from rear light (2).
Clean bonding surface and allow to dry.
Installation:
Make sure seal (1) is correctly bonded all round on rear light (2).
2007 BMW 335i
Fig. 53: Identifying Seal And Rear Light

63 21 101 REPLACING SEALING FRAME FOR LEFT OR RIGHT REAR LIGHT (ON SIDE PANEL)
(CONVERTIBLE)
Installation:

63 21 104 REPLACING SEALING FRAME FOR LEFT OR RIGHT REAR LIGHT (ON REAR LID)
2007 BMW 335i
(COUPE)
Installation:
Fig. 55: Identifying Rear Light And Seal

63 21 104 REPLACING SEALING FRAME FOR LEFT OR RIGHT REAR LIGHT (ON REAR LID)
(CONVERTIBLE)
Installation:
2007 BMW 335i

63 21 180 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT REAR LIGHT (IN SIDE
PANEL) (COUPE)
Protection).
Unlock locking clip (2) in direction of arrow and remove socket housing (3) from rear light.
2007 BMW 335i
Fig. 58: Identifying Locking Clip, Plug Connection, Socket Housing And Removal Direction
Release nut (1), for tightening torque refer to 63 21 1AZ in 63 21 REAR LIGHT UNIT .
Remove spacer (2).
Release nuts (3), for tightening torque refer to 63 21 1AZ in 63 21 REAR LIGHT UNIT .
Remove rear light (4) in outwards direction from side panel (5).
Installation:
Make sure gap is uniform all round between rear light (4) and side panel (5).
Observe tightening sequence, first inside then outside.
Fig. 59: Identifying Rear Light, Nuts, Spacer And Side Panel
Installation:
Make sure seal (1) is correctly seated on rear light (2).

2007 BMW 335i

63 21 180 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT REAR LIGHT (IN SIDE
PANEL) (CONVERTIBLE)
Protection).

Unscrew nuts (2). Tightening torque: see 1AZ in 63 21 REAR LIGHT UNIT .
Remove rear light (3) in outwards direction from side panel.
Installation:
2007 BMW 335i
Make sure gap is uniform all round between rear light (3) and side panel.
Observe tightening sequence, first inside then outside.
Fig. 62: Identifying Rear Light, Connector, And Nuts

Replacement:
If necessary, remove bulbs.
63 21 180 REMOVING AND REFITTING/REPLACING LEFT OR RIGHT REAR LIGHT AS FITTED

FROM 03/2010 (ON SIDE PANEL)
IMPORTANT: Read and comply with NOTES ON PROTECTION AGAINST ELECTROSTATIC

DAMAGE (ESD PROTECTION) .
2007 BMW 335i
Unscrew nuts (2).
Fig. 64: Identifying Nuts And Connector

Remove rear light (1) rearwards from side panel (2).
Installation note:
Make sure gap is uniform all round between rear light (1) and side panel (2).
Fig. 65: Identifying Side Panel And Rear Light

Installation note:
2007 BMW 335i
Fig. 66: Identifying Rear Light And Seal

63 21 183 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT TAIL LIGHT (ON REAR
LID) (COUPE)
Protection).
Release nut (1) and remove with retaining bar (2).
For tightening torque refer to 63 21 3AZ in 63 21 REAR LIGHT UNIT .
Installation:
Make sure retaining bar (2) is correctly seated on rear lid (3).
Fold rear light (4) outwards out of rear lid (3).
Disconnect associated plug connection.
Remove rear light (4).
Installation:
Position lugs (5) of rear light (4) exactly over side edge of rear lid (3).
2007 BMW 335i
Fig. 67: Identifying Rear Light, Lugs, Rear Lid, Nut And Retaining Bar
Installation:

63 21 183 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT TAIL LIGHT (ON REAR
LID) (CONVERTIBLE)
Protection). .
 Partially remove trim panel for rear lid .

2007 BMW 335i
Release nut (2) and remove with retaining bar (3).
Tightening torque: see 3AZ in 63 21 rear light unit .
Remove rear light.
Installation:
Position lugs (4) of rear light exactly over side edge of rear lid.
Make sure retaining bar (3) is correctly seated on rear lid.
Fig. 69: Identifying Connector, Lugs, Nut, And Retaining Bar

Replacement:
BRAKE LIGHTS
63 25 000 REMOVING AND INSTALLING/REPLACING AUXILIARY BRAKE LIGHT (COUPE)
Unclip auxiliary brake light cover (1) at retaining points (3). Remove auxiliary brake light cover (1) in direction
of arrow from roofliner (2).
2007 BMW 335i
Fig. 70: Identifying Brake Light Cover, Retaining Points, Roofliner And Removal Direction
Installation:
Retaining hooks (3) and guides (2) of auxiliary brake light cover (1) must not be damaged.
Make sure cover for auxiliary brake light (1) is correctly seated.
Fig. 71: Identifying Auxiliary Brake Light, Retaining Hooks And Guides
Unlock slide (2) in direction of arrow and remove auxiliary brake light (4) from rear window (3).
Installation:
Make sure auxiliary brake light (4) is correctly positioned on rear window (3).
2007 BMW 335i
Fig. 72: Identifying Slide, Rear Window, Plug Connection, Brake Light And Removal Direction
63 25 000 REMOVING AND INSTALLING/REPLACING AUXILIARY BRAKE LIGHT

(CONVERTIBLE)
 Remove panel for rear lid
Release nuts (3) and remove springs (2) underneath.
Press auxiliary brake light at threaded pins (4) outwards and remove.
Installation:
Make sure auxiliary brake light seal is correctly seated.
Tighten nuts (2) from inside outwards.
Tightening torque: 2.5 Nm +/- 0.5 Nm

2007 BMW 335i
Fig. 73: Identifying Pins, Nuts, Springs, And Connector

LICENCE PLATE LIGHTS

63 26 000 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT NUMBER/LICENSE
PLATE LIGHT
 64 1 020
WARNING: Follow instructions for handling light bulbs (Exterior Lights).
Lever license plate light (1) with special tool 64 1 020 out of rear bumper trim (2).
Unlock plug connection underneath and disconnect.
Remove license plate light (1).
Replacement:
 If necessary, remove Bulb.

 Note Bulb Type
2007 BMW 335i
Fig. 74: Identifying License Plate Light, Special Tool (64 1 020) And Removal Direction
INTERIOR LIGHTS
63 31.. OVERVIEW OF INTERIOR LIGHTS
2007 BMW 335i
Fig. 75: Identifying Interior Lights Components Location

63 31 000 REMOVING AND INSTALLING OR REPLACING COMPLETE ROOF LIGHT (FRONT)
 00 9 341
IMPORTANT: Follow instructions for handling light bulbs (Interior Lights).
Version with roof switch cluster:
Operation is described in Removing and in stalling or replacing Roof Switch Cluster .

2007 BMW 335i
Fig. 76: Identifying Roof Switch Cluster And Special Tool (00 9 341)
Version without roof switch cluster:
Lever roof light (1) with special tool 00 9 341 out of roof liner (2).
Disconnect associated plug connection and remove roof light (1).
Fig. 77: Identifying Roof Liner, Roof Light And Special Tool (00 9 341)
Replacement:
 If necessary, convert Bulbs.

 Note Bulb Type.
63 31 003 REMOVING AND INSTALLING/REPLACING COMPLETE CEILING LIGHT (REAR)

2007 BMW 335i
 00 9 317
Carefully unlock both retainers on left/right with special tool 00 9 317 and lever out ceiling light (1).
Disconnect plug connection underneath and remove ceiling light (1) from roofliner.
Replacement:

 Note Bulb Type
Fig. 78: Identifying Ceiling Light And Special Tool (00 9 317)
63 31 004 REMOVING AND INSTALLING OR REPLACING COMPLETE ROOF LIGHT (REAR,

WITH MODULE FOR PASSENGER COMPARTMENT PROTECTION)
 00 9 341
Risk of damage!
Carry out operations carefully.
Carefully lever out roof light trim (1) with special tool 00 9 341.
Reflector underneath must not be damaged.

2007 BMW 335i
Fig. 79: Identifying Roof Light Trim, Special Tool (00 9 341) And Removal Direction
Version with reading lights:
Retainer (1) is on centerline of reading light.
Fig. 80: Identifying Retainer, Roofliner, Reflector, Special Tool (00 9 341) And Removal Direction
Version without reading lights:
Retainer (1) is at distance (A) from outer edge of roof light/reading light.
(A) 3.5 cm =
2007 BMW 335i
Fig. 81: Identifying Retainer, Reflector, Roof Liner, Distance, Special Tool (00 9 341) And Removal
Direction
Lever out ceiling light (1) with special tool 00 9 341.
Disconnect plug connection underneath.
Remove ceiling light (1) from roofliner (2).
Fig. 82: Identifying Ceiling Light, Roofliner, Special Tool (00 9 341) And Removal Direction
Installation:
Assemble roof light prior to installation:

2007 BMW 335i
 Feed in roof light trim (1) at line (2)

 Press roof light trim (1) in direction of arrow onto roof light (3)
Make sure roof light trim (1) is correctly seated.
Fig. 83: Identifying Ceiling Light Trim, Line, Ceiling Light And Assembly Direction
Replacement:
 Remove Module For Passenger Compartment Protection

 Note Bulb Type
63 31 020 REMOVING AND INSTALLING/REPLACING FOOTWELL LIGHT (DOOR)
IMPORTANT: Follow instructions for handling light bulbs (Interior Lights)..
Lever footwell light (1) in direction of arrow out of door trim (2).
Disconnect associated plug connection and remove footwell light (1).
Replacement:

 Note Bulb Type.
2007 BMW 335i
Fig. 84: Identifying Footwell Light And Door Trim

63 31 020 REMOVING AND INSTALLING/REPLACING FOOTWELL LIGHT (FOOTWELL)
 64 1 020
Lever out footwell light (1) with special tool 64 1 020 as illustrated.
Disconnect associated plug connection and remove footwell light (1).
Replacement:

 Note Bulb Type.
2007 BMW 335i
Fig. 85: Identifying Footwell Light, Special Tool (64 1 020) And Removal Direction
63 31 023 REMOVING AND INSTALLING/REPLACING FOOTWELL LIGHT (ON STORAGE

COMPARTMENT AT REAR)
 00 9 340
Lever out footwell light (1) with special tool 00 9 340 in direction of arrow.
Disconnect plug connection and remove footwell light (1).
Replacement:

 Note Bulb Type.
Fig. 86: Identifying Footwell Light And Special Tool (00 9 340)
63 31 050 REMOVING AND INSTALLING/REPLACING MIRROR LIGHT (COUPE)
 00 9 341
Lever mirror light (1) with special tool 00 9 341 in direction of arrow out of roofliner (2).
2007 BMW 335i
Disconnect plug connection underneath and remove mirror plate light (1).
Replacement:
 If necessary, modify Bulb

 Note Bulb Type.
Fig. 87: Identifying Mirror Light, Roofliner, Special Tool (00 9 341) And Removal Direction
63 31 050 REMOVING AND INSTALLING/REPLACING MIRROR LIGHT (CONVERTIBLE)
IMPORTANT: Follow instructions for handling light bulbs (interior lights).
Lever mirror light (1) with special tool 00 9 341 in direction of arrow out of upper cowl panel trim (2).
Disconnect plug connection (3) and remove mirror light (1).
Replacement:

2007 BMW 335i
Fig. 88: Levering Mirror Light Using Special Tool 00 9 341

63 31 080 REMOVING AND INSTALLING/REPLACING LUGGAGE COMPARTMENT LIGHT

(COUPE)
Lever out luggage compartment light (1) in direction of arrow with special tool 64 1 020.
Disconnect associated plug connection and remove luggage compartment light (1).
Fig. 89: Identifying Luggage Compartment Light, Special Tool (64 1 020) And Removal Direction
Replacement:
 If necessary, modify bulb

 Note Bulb Type.

2007 BMW 335i
(CONVERTIBLE)
Pry out luggage compartment light (1) in direction of arrow.
Fig. 90: Prying Out Luggage Compartment Light

Replacement:
 If necessary, modify bulb.
Note type of bulb (see Fig. 91).

2007 BMW 335i
Fig. 91: Identifying Interior Lighting Bulb Types - E93


(REAR LID) (CONVERTIBLE)
Lever out luggage compartment light (1) in direction of arrow.
Fig. 92: Removing Luggage Compartment Light

2007 BMW 335i
Replacement:
 If necessary, modify bulb.

63 31 150 REMOVING AND INSTALLING/REPLACING GLOVEBOX LIGHT
Lever out glovebox light (1) in direction of arrow.
Disconnect plug connection and remove glovebox light (1).
Replacement:
 If necessary, remove bulb.

 Note Bulb Type.
2007 BMW 335i
Fig. 94: Identifying Glovebox Light

63 31 170 REMOVING AND INSTALLING/REPLACING DOOR HANDLE LIGHT ON LEFT OR

RIGHT FRONT DOOR
 Remove Sound Insulation From Front Door

 Remove Cover On Front Outside Handle
 Remove Door Lock On Front Door
NOTE: Inner door panel partially shown transparent.
Unclip wiring harness (2) from carrier for outside door handle (3).
Raise outside door handle (4) slightly and remove.
Fig. 95: Identifying Wiring Harness, Carrier, Plug Connection And Outside Door Handle
2007 BMW 335i
Installation:
Make sure door handle light (1) is correctly positioned in area (2).
Guides (3) of door handle light (1) must be seated in carrier for outside door handle (4).
Fig. 96: Identifying Guides, Door Handle Light, Area And Carrier
Installation:
Make sure wiring harness (1) is laid correctly.
Wiring harness holders (2) must not be damaged.
Replacement:
Undo loop (3) to obtain the required cable length.

2007 BMW 335i
Fig. 97: Identifying Wiring Harness, Holders And Loop

63 31 180 REPLACING LED FOR FRONT DOOR TRIM PANEL LIGHT
Unlock LED (1) at catch (2) and detach in direction of arrow from fibre-optic waveguide (3).
Installation:
LED (1) must snap noticeably in to fibre-optic waveguide (2).
Fig. 98: Identifying LED, Fibre-Optic Waveguide And Catch

63 31 185 REPLACING LED FOR SIDE TRIM PANEL LIGHT

 Remove Armrest Side Section On Rear Seat Backrest
Detach LED for side trim panel light (1) in direction of arrow from fibre optic cable (2).
Installation:
LED for side trim panel light (1) must be felt to snap into place in fibre optic cable (2).
2007 BMW 335i
Fig. 99: Identifying Side Trim Panel Light LED, Fibre Optic Cable And Removal Direction
LIGHT BULBS
63 99... NOTES FOR REPLACING THE PROTECTIVE CAP OF THE HEADLIGHT

Damaged seals on the protective caps will lead to moisture penetration into the
headlight.
This will in turn cause porous cable insulations and malfunctioning of the
headlight.
When working on the headlight system, check the protective cap seals.
Replace the protective cap in the event of damage!
Example: screwed protective cap
Seal (1) on protective cap (2).

2007 BMW 335i
Fig. 100: Identifying Seal On Protective Cap (Screwed Protective Cap)

Example: latchable protective cap
Seal (1) on protective cap (2).
Fig. 101: Identifying Seal On Protective Cap (Latchable Protective Cap)

63 99... INSTRUCTIONS FOR HANDLING LIGHT BULBS (EXTERIOR LIGHTS)
WARNING: Xenon headlights: Danger to life due to high voltage!

2007 BMW 335i
WARNING: Halogen lamps are under pressure:
To avoid injury, wear protective goggles and gloves.
IMPORTANT: To prevent short-circuiting, disconnect light bulbs from voltage supply prior to
replacement.
Do not touch the glass bulbs in new lights bulbs as even the slightest contamination will burn in and reduce bulb
service life.
Only touch light bulbs with clean gloves or a clean cloth.
Do not expose light bulbs to mechanical vibrations.
Use only recommended light bulbs.
Follow the light bulb manufacturer's instructions without fail.
63 99... INSTRUCTIONS FOR REPLACING LIGHT BULBS (INTERIOR LIGHTS)
CAUTION: To prevent short-circuiting, disconnect light bulbs from voltage supply

prior to replacement.
Do not touch the glass bulbs in new lights bulbs as even the slightest contamination will burn in and reduce bulb
service life.
Only touch light bulbs with clean gloves or a clean cloth.
Do not expose light bulbs to mechanical vibrations.
Use only recommended light bulbs.
Follow the light bulb manufacturer's instructions without fail.
63 99 072 REPLACING HALOGEN BULB FOR LEFT OR RIGHT HEADLIGHT (FROM VERSION
9/2008)
WARNING: Comply with notes on handling bulbs (exterior lights).
Unlock and remove cover (1).

2007 BMW 335i
Fig. 102: Unlocking And Removing Cover

Turn protective cap (1) counterclockwise and remove.
IMPORTANT: Risk of damage due to moisture penetration!
Installation note:
Check seal. Replace protective cap (1) if necessary.
Comply with Notes for replacing the protective cap of the headlight.
Protective cap (1) must lock correctly!
Turn the protective cap (1) clockwise to end stop (A)!
Fig. 103: Turning Protective Cap Clockwise To End Stop

2007 BMW 335i
Turn bulb holder (1) in direction of arrow and pull out towards rear.
Installation note:
Make sure retaining tabs (2) in headlight are correctly seated.
Fig. 104: Identifying Bulb Holder And Retaining Tabs

Detach bulb (1) from bulb holder (2).
Installation note:
Note bulb type .
Fig. 105: Detaching Bulb From Bulb Holder

63 99 076 REPLACING BULB FOR LEFT (OR RIGHT) XENON HEADLIGHT (WITH IGNITION
UNIT)
2007 BMW 335i
Replacing Ignition Unit For Left Xenon Headlight.
63 99 145 REPLACING BULB FOR FRONT LEFT (OR RIGHT) PARKING LIGHT
WARNING: Follow instructions for handling light bulbs (exterior lights).
Unlock retainer (1) and remove cover (2) in direction of arrow from headlight.
Installation:
Make sure cover (2) is correctly seated on headlight.
Fig. 106: Identifying Retainer, Cover And Removal Direction

Grip bulb holder (2) on both sides, turn in direction of arrow and pull out of headlight.
Installation:
 Make sure bulb holder (2) is exactly seated in headlight.

 Note Bulb Type.
2007 BMW 335i
Fig. 107: Identifying Plug Connection, Bulb Holder And Removal Direction
63 99 160 REPLACING BULB FOR FRONT LEFT (OR RIGHT) TURNING LIGHT
Unlock retainer (1) and remove cover (2) in direction of arrow from headlight.
Installation:
Make sure cover (2) is correctly seated on headlight.
Fig. 108: Identifying Retainer, Cover

Disconnect locking clip (2) and fold upwards.

2007 BMW 335i
Remove bulb (3) from headlight.
Installation:
 Note Bulb Type.
Fig. 109: Identifying Bulb, Locking Clip, Plug Connection And Removal Direction
63 99 201 REPLACING HALOGEN BULB FOR LEFT OR RIGHT FRONT FOG LAMP
 Remove front Wheel Arch Cover
Turn bulb (2) in direction of arrow and remove from fog lamp (3).
Installation:
Note Bulb Type.

2007 BMW 335i
Fig. 110: Identifying Plug Connection, Bulb And Fog Lamp

63 99 273 REPLACING BULB FOR LEFT (OR RIGHT) FRONT TURN INDICATOR
 If necessary, remove Front wheel arch cover
Turn locks (1) counterclockwise through 180°.
Remove repair cover (2) from wheel arch cover (3).
Installation:
Make sure guides (4) of repair cover (2) are correctly seated in wheel arch cover (3).
Fig. 111: Identifying Guides Of Repair Cover

2007 BMW 335i
Turn direction indicator bulb holder (1) in direction of arrow and pull out of headlight.
Fig. 112: Removing Bulb Holder From Headlight

Twist bulb for front direction indicator (1) in direction of arrow and remove from direction indicator bulb
holder (2).
Installation:
Make sure bulb for front direction indicator (1) and sealing ring (3) are correctly seated on direction indicator
bulb holder (2).
Note type of bulb .
Fig. 113: Identifying Sealing Ring On Indicator Bulb Holder

63 99 295 REPLACING BULB FOR AUXILIARY TURN SIGNAL LIGHT, FRONT LEFT OR RIGHT
2007 BMW 335i
 Remove Front Auxiliary Turn Signal Light
Unlock retaining lug (1).
Turn bulb holder (2) in direction of arrow and remove from auxiliary turn signal light (3).
Pull bulb out of holder (2).
Fig. 114: Identifying Retaining Lug, Bulb Holder, Signal Light And Removal Direction
Installation:
 Detent lug must not be damaged

 Make sure bulb holder is correctly seated and engaged in auxiliary direction indicator
 Note Bulb Type
63 99 315 REPLACING LIGHT BULB(S) FOR LEFT OR RIGHT REAR LIGHT (COUPE)
Rear light in side panel:
Remove Socket Housing For Rear Light.
Turn bulb (1) and pull out of socket housing for rear light (5).
2007 BMW 335i
Pull bulbs (2, 3, 4) out of socket housing for rear light (5).
NOTE:  Bulb, direction indicator light (1)

 Bulb, reversing light (2)
 Bulb, brake light (3)
 Bulb, adaptive brake light (4)
Fig. 115: Identifying Bulbs And Socket Housing For Rear Lights
Rear light in rear lid:
Remove Panel For Rear Lid.
Turn bulb holder (1) in direction of arrow and pull out of rear light (2).
Fig. 116: Identifying Bulb Holder, Light And Removal Direction

Turn bulb (1) and pull out of bulb holder (2).

2007 BMW 335i
NOTE:  Bulb, rear fog light (1)
Fig. 117: Identifying Bulb, Bulb Holder And Removal Direction

Installation:
Note type of Bulb.
63 99 315 REPLACING LIGHT BULB(S) FOR LEFT OR RIGHT REAR LIGHT (CONVERTIBLE)
Rear light in side panel:

2007 BMW 335i

Turn bulb (1) and pull out of socket housing (2).
Note type of bulb (see Fig. 123
Fig. 120: Removing Bulb From Socket Housing

Rear light in rear lid:
Remove trim on rear lid .
Turn bulb holder (1) in direction of arrow and pull out of rear light (2).
2007 BMW 335i
Fig. 121: Turning Bulb Holder In Direction Of Arrow

Turn bulb (1) and pull out of bulb holder (2).
NOTE:  Bulb, rear fog light (1)
Fig. 122: Identifying Bulb, Rear Fog Light

Installation:
Note type of bulb (see Fig. 123

2007 BMW 335i
Fig. 123: Identifying Rear Light Unit Bulb Types - E93

63 99 401 REPLACING BULB FOR LEFT OR RIGHT LICENSE PLATE LIGHT
 Remove License Plate Light
Spread bow contacts (1) and remove festoon bulb (2).
Installation:
Note Bulb Type.

2007 BMW 335i
Fig. 124: Identifying Festoon Bulb And Bow Contacts

63 99 431 REPLACING BULB FOR FRONT CEILING LIGHT (COUPE)
WARNING: Follow instructions for handling light bulbs (Interior Lights).
 Remove Front Ceiling Light
Turn bulb holder in direction of arrow and remove.
Fig. 125: Identifying Bulb Holder And Removal Direction

Pull bulb (1) out of bulb holder (2).

2007 BMW 335i
Fig. 126: Identifying Bulb, Holder, And Removal Direction

Installation:
 Make sure bulb holder is correctly seated and engaged in ceiling light
 Note Bulb Type
63 99 431 REPLACING BULB(S) FOR CEILING LIGHT (ROOF SWITCH CENTER)

(CONVERTIBLE)
WARNING: Follow instructions for handling light bulbs (interior lights).
 Remove roof switch cluster .
Turn bulb holders in direction of arrow and pull out of roof switch center.
Installation:
Make sure bulb holders are correctly seated and engaged in roof switch center.
2007 BMW 335i
Fig. 127: Turning Bulb Holders

Fig. 128: Pulling Bulb Out Of Bulb Holder

Installation:

2007 BMW 335i

63 99 432 REPLACING BULB FOR REAR CEILING LIGHT
 Remove Rear Ceiling Light
Turn bulb holder in direction of arrow and remove.

2007 BMW 335i
Fig. 130: Identifying Bulb Holder And Removal Direction

Fig. 131: Identifying Bulb, Holder And Removal Direction

Installation:
 Make sure bulb holder is correctly seated and engaged in ceiling light
 Note Bulb Type
63 99 437 REPLACING LIGHT BULB FOR FOOTWELL LIGHT
WARNING: Follow instructions for handling light bulbs (Interior Lights)..

2007 BMW 335i
 Remove Footwell Light
In footwell:
Pull bulb (1) in direction of arrow out of bulb holder.
Installation:
Note bulb type
Fig. 132: Identifying Footwell Bulb And Removal Direction

On underside of door:
Turn bulb holder (1) in direction of arrow and pull out of footwell light (2).
Installation:
Make sure bulb holder (1) is correctly engaged on footwell light (2).
Fig. 133: Identifying Bulb Holder On Footwell Light

2007 BMW 335i
Pull bulb (1) in direction of arrow out of bulb holder (2).
Installation:
Note bulb type
Fig. 134: Removing Bulb Of Bulb Holder

On rear floor trim:
Unlock catch (1) on footwell light (2).
Open bulb holder (3) in direction of arrow.
Fig. 135: Identifying Catch On Footwell Light

Pull bulbs (1) in direction of arrow out of bulb holder (2).

2007 BMW 335i
Installation:
Note bulb type
Fig. 136: Identifying Bulbs In Direction Of Arrow

63 99 445 REPLACING BULB FOR MIRROR LIGHT (COUPE)
 Remove Mirror Light
Spread bow contacts (1) and remove bulb.
Installation:
Note Bulb Type.

2007 BMW 335i
Fig. 137: Identifying Contacts, Bulb And Removal Direction

63 99 445 REPLACING BULB FOR MIRROR LIGHT (CONVERTIBLE)
 Remove mirror light
Pull bulbs (1) in direction of arrow out of mirror light.
Fig. 138: Pulling Mirror Light Bulbs

Installation:

2007 BMW 335i

63 99 451 REPLACING LIGHT BULB FOR LUGGAGE COMPARTMENT LIGHTING
 Remove luggage compartment light. See procedure for coupe or convertible.
Version A:
Move lens cover (1) in direction of arrow and remove.
Remove festoon (2) underneath.
Installation:

2007 BMW 335i

Fig. 141: Identifying Festoon & Lens Cover

Version B:
Release lens cover (1) at latch mechanisms (2) on both sides.
Remove lens cover (1) from luggage compartment light (3) in direction of arrow.
2007 BMW 335i
Fig. 142: Removing Lens Cover From Luggage Compartment Light

Push bulb (1) out of socket with a suitable tool (e.g. screwdriver 3 mm blade) in direction of arrow and remove.
Fig. 143: Pushing Bulb Out Of Socket

Check headlight lens cover (1) before fitting. If necessary, carefully press together both side tabs a little in
direction of arrow.
2007 BMW 335i
Fig. 144: Checking Headlight Lens Cover Before Fitting

63 99 452 REPLACING LIGHT BULB FOR LUGGAGE COMPARTMENT LIGHT (ON REAR LID)
(CONVERTIBLE)
WARNING: Follow instructions for handling light bulbs (interior lights).
 Remove luggage compartment light (on rear lid)
Turn bulb holder (1) in direction of arrow and pull out of luggage compartment light (2).
Fig. 145: Identifying Bulb Holder And Luggage Compartment Light

Pull bulb (1) in direction of arrow out of bulb holder (2).

2007 BMW 335i
Fig. 146: Identifying Bulb Holder And Bulb

Installation:

63 99 461 REPLACING BULB FOR GLOVEBOX LIGHT

2007 BMW 335i
 Remove Glovebox Light
Spread bow contacts (1) and remove bulb.
Installation:
Note Bulb Type.
Fig. 148: Identifying Contacts, Bulb And Removal Direction

2007 BMW 335i
TRANSMISSION Manual Transmission - Repair - N54
TRANSMISSION
Manual Transmission - Repair - N54
TRANSMISSION IN GENERAL
 Headaches
 Dizziness
 Stomach aches
 Vomiting
 Diarrhoea
 Cramps/fits
 Unconsciousness

First aid measures
00 11..... DRAINING/TOPPING UP TRANSMISSION OIL IN MANUAL GEARBOX
NOTE: Transmission must be at operating temperature.

Transmission oil:
 refer to BMW Service Operating Fluids . See MANUAL TRANSMISSION -

OPERATING FLUIDS .
2007 BMW 335i
Filling capacities:
 Refer to MANUAL TRANSMISSION - TECHNICAL DATA (N54) .
Draining transmission oil:
 Release oil drain plug (1) and filler plug (2).

 Clean oil drain plug (1) and screw in.
Fill transmission with transmission oil.
 Pour in gear oil until overflowing.

 Screw in oil filler plug (2).
Fig. 1: Identifying Oil Drain Plug And Filler Plug

23 00 036 INSTALLING REPLACEMENT TRANSMISSION (GS6-37BZ) AWD
IMPORTANT: After completion of work, check TRANSMISSION FLUID LEVEL.

Use only the approved transmission fluid . See MANUAL TRANSMISSION -
OPERATING FLUIDS .
Recycling:
2007 BMW 335i
Catch and dispose of escaping transmission fluid.
Observe country-specific waste-disposal regulations
 Drain gear oil at oil drain plug. Tightening torque: 23 00 4AZ .

 Remove transfer case . See 2710010 REMOVING AND INSTALLING TRANSFER CASE (ATC
300) .
 Remove transmission.
Convert following parts from previous transmission to new transmission.
 Release bearing and release lever . See 2151500 REMOVING AND INSTALLING OR
REPLACING CLUTCH RELEASE BEARING/LEVER (E90) , 21 51 500 REMOVING AND
INSTALLING OR REPLACING CLUTCH RELEASE BEARING/LEVER (E90/E91) or 21 51 500
REMOVING AND INSTALLING OR REPLACING CLUTCH RELEASE BEARING/LEVER
(E92/E93) .
 Knurled pin for clutch slave cylinder.
 Reversing light switch, tightening torque: 23 41 5AZ .
Convert shift rod joint.
Push back retaining ring (1) and drive out dowel pin (2).
Fig. 2: Identifying Retaining Ring And Dowel Pin

NOTE: Check damping disk (6) for damage and replace if necessary.
2007 BMW 335i
Fig. 3: Identifying Damping Disk

Check oil level.
Installation:
Observe greasing specification.
23 00 037 INSTALLING REPLACEMENT TRANSMISSION (GS6-53BZ/DZ) AWD
IMPORTANT: After completion of work, check transmission oil level . See 00 11 229 OIL
CHANGE IN MANUAL TRANSMISSION or 00 11..... DRAINING/TOPPING UP
TRANSMISSION OIL IN MANUAL GEARBOX.
Use only the approved transmission fluid . See MANUAL TRANSMISSION -
OPERATING FLUIDS .
Recycling
Catch and dispose of escaping transmission fluid.
 Drain gear oil at oil drain plug. Tightening torque: 23 00 4AZ .

 REMOVE GEARBOX.
 Remove transfer box . See 2710010 REMOVING AND INSTALLING TRANSFER CASE (ATC
2007 BMW 335i
300) .
Release screws.
Remove and convert transmission bearing block.
NOTE: Illustration shows E46.
Fig. 4: Locating Transmission Bearing Block Bracket Bolts

Convert shift rod joint.
Push back retaining ring (1) and drive out dowel pin (2).
Fig. 5: Identifying Retaining Ring And Dowel Pin

2007 BMW 335i
NOTE: Check damping disk (6) for damage and replace if necessary.
Fig. 6: Identifying Damping Disk

Convert following parts from previous transmission to new transmission.
 Release bearing and release lever . See 2151500 REMOVING AND INSTALLING OR
(E92/E93) .
 Ball pin and spring wire clip.
 Studs for clutch slave cylinder.
 Reversing light switch tightening torque: 23 41 5AZ .
Check oil level.
Installation:
Observe greasing specification .
00 11 229 OIL CHANGE IN MANUAL TRANSMISSION
NOTE: Gearbox must be at normal operating temperature.

Gear oil:
 Refer to BMW Service Operating Fluids. See MANUAL TRANSMISSION -

2007 BMW 335i
OPERATING FLUIDS .
Filling capacities:
 Refer to MANUAL TRANSMISSION - TECHNICAL DATA (N54) .
Draining gear oil:
 Release oil drain plug (1) and filler plug (2).

 Clean oil drain plug (1) and screw in.
Fill transmission with ATF.
 Pour in gear oil until overflowing.

 Tighten in filler screw (2).
Fig. 7: Identifying Oil Drain Plug And Filler Plug

23 00... OVERVIEW OF TRANSMISSION HOUSING (GS6-53BZ/DZ)

2007 BMW 335i
Fig. 8: Identifying Transmission Housing Components

23 00 018 REMOVING AND INSTALLING TRANSMISSION (GS6-53BZ) N54 4WD

2007 BMW 335i
 00 2 030
 00 9 010
 00 9 120
 00 9 130
 21 2 240
 23 4 050

Use only the approved transmission oil . See MANUAL TRANSMISSION -
OPERATING FLUIDS .
Failure to comply with this requirement will result in serious damage to the manual gearbox.
IMPORTANT: Aluminium screws/bolts must be replaced each time they are released .
Aluminium screws/bolts are permitted with and without colour coding (blue).
Aluminium screws/bolts are not magnetic .
damage) .
In vehicles with an N54/N55 engine from production date 09/2012, only steel
bolts are installed.
 Clamp off battery . See 6120900 DISCONNECTING AND CONNECTING BATTERY

 Remove front underbody protection.
(E92/E93) .
 Remove rear propeller shaft from transmission. See 26 11 000 REMOVING AND INSTALLING
COMPLETE PROPELLER SHAFT (FLEXIBLE DISC AT REAR) (AWD) , 2611000
2007 BMW 335i
REMOVING AND INSTALLING PROPELLER SHAFT (CARDAN UNIVERSAL JOINT)

COMPLETELY (E90) or 26 11 000 REMOVING AND INSTALLING PROPELLER SHAFT
(CARDAN UNIVERSAL JOINT) COMPLETELY (E90/E91) or 26 20 000 REMOVING AND
INSTALLING FRONT PROPELLER SHAFT (E92/E93) .
 Release centre mount.
NOTE:  Bending the propeller shaft by an excessive angle can cause premature
 Tie up propeller shaft to underbody.
 Support engine with jack when removing gearbox
Remove holder (1-3).

Release screws (1).
Steel screws, tightening torque 23 00 1AZ .
Aluminium screws, tightening torque 23 00 2AZ .
Release aluminium screws with special tool 00 9 010 .

2007 BMW 335i
Fig. 10: Identifying Screws And Connector

Release screws (1).
Remove holder (2).
Fig. 11: Identifying Screws And Holder

Unlock connector (1) from reversing light switch and detach.
Release cable from brackets.
NOTE: Graphic similar.

2007 BMW 335i
Fig. 12: Identifying Reversing Light Switch Connector


Tasks are described in gearbox holder.

2007 BMW 335i
Release screws.
Remove transmission cross member.
Fig. 15: Locating Transmission Cross Member Bolts

Disconnect plugs (1) and (2) from servomotor.

2007 BMW 335i
Fig. 16: Identifying Servomotor Plugs

NOTE: Pressure line of clutch slave cylinder remains connected.
IMPORTANT: Relieve tension on clutch slave cylinder slowly; otherwise air will be drawn in
through sealing cup.
Release nuts and remove clutch slave cylinder.
Fig. 17: Locating Clutch Slave Cylinder Nut

Lever out retainer (1).
Disengage gearshift rod (2).

2007 BMW 335i
Installation note:
Grease gearshift rod.
Grease, refer to BMW Service Operating Fluids . See MANUAL TRANSMISSION - OPERATING
FLUIDS .
Make sure shims (3) are in correct position.
Fig. 18: Disengaging Gearshift Rod

Unlock bearing journal (1) in direction of arrow and remove.
Lift out gearshift arm.
Installation note:
Grease bearing journals (1).
Grease, refer to BMW Service Operating Fluids . See MANUAL TRANSMISSION - OPERATING
FLUIDS .
2007 BMW 335i
Fig. 19: Unlocking Bearing Journal

Release screws.
In vehicles with an N54/N55 engine from production date 09/2012, only steel bolts are installed.
Steel screws, tightening torque 23 00 1AZ .
Aluminium screws/bolts (3, 4, 5, 9, 10), tightening torque 23 00 2AZ .
IMPORTANT: Do not suspend the transmission from the transmission input shaft during
removal and installation as this will deform the clutch disc. Pull out
transmission towards rear and remove.
Fig. 20: Identifying Transmission Screws/Bolts

2007 BMW 335i
Installation note:
Special angle-of-rotation tool 00 9 120 with magnet 00 9 130 .
Secure to vehicle underbody and screw down aluminium screws/bolts in accordance with angle of rotation.
Fig. 21: Identifying Special Angle-Of-Rotation Tool (00 9 120) And Magnet (00 9 130)
Installation note:
Check that fitting sleeves are correctly fitted.
Ensure correct position of cover plate.

2007 BMW 335i
Fig. 22: Identifying Cover Plate Fitting Sleeves

Installation note:
Check lubrication of transmission input shaft for sticky consistency. If grease is sticky, clean drive shaft and
replace clutch disc . See 2121500 REMOVING AND INSTALLING OR REPLACING CLUTCH (SAC
228) (E90) , 21 21 500 REMOVING AND INSTALLING OR REPLACING CLUTCH (SAC 228)
(E90/E91) or 21 21 500 REMOVING AND INSTALLING OR REPLACING CLUTCH (SAC 228)
(E92/E93) .
Check clutch disc for friction rust in gearing and replace if necessary.
Mechanically remove existing grease and lining abrasion from gearings of clutch disc (with a cloth).
Fig. 23: Locating Transmission Input Shaft

Installation note:
2007 BMW 335i
Greasing specification:
 Remove and clean release bearing and release lever . See 2151500 REMOVING AND INSTALLING
OR REPLACING CLUTCH RELEASE BEARING/LEVER (E90) , 21 51 500 REMOVING AND
(E92/E93) .
 Push on grease scraper ring 21 2 240 until limit position.
 Grease gearing (1) of input shaft with a brush. Refer to BMW Service Operating Fluids . See
MANUAL TRANSMISSION - OPERATING FLUIDS .
 Detach grease scraper ring.
Fig. 24: Identifying Grease Gearing And Grease Scraper Ring (21 2 240)
23 01 010 REPLACING SEALING CAP (GS6-17BG/DG)
 23 0 490
 23 0 330
 Remove clutch release bearing/lever . See 2151500 REMOVING AND INSTALLING OR
(E92/E93) .
Drive a hole into the sealing cap (1) with a suitable tool (2).
2007 BMW 335i
IMPORTANT: Do not use a drill as drillings may result in transmission malfunction.
Fig. 25: Identifying Zero Gear Sensor Plug Connection And Screws
Screw special tool 23 0 490 into sealing cap.
Withdraw sealing cap from transmission housing with aid of impact weight.
Fig. 26: Locating Guide Tube Screws

Apply transmission oil to the sealing lip of the sealing cap (1) and insert.
2007 BMW 335i
Fig. 27: Identifying Guide Tube Sticker

Drive sealing cap firmly home with special tool 23 0 330 .
Fig. 28: Locating Guide Tube Screws

Danger of injury!
 Impaired sight
2007 BMW 335i


First aid measures

Recycling
Measures if oil is unintentionally released
23 TRANSMISSION DESIGNATIONS
Breakdown of BMW designation
A5S 300J (former designation)
2007 BMW 335i
A Transmission type  A = Automatic transmission

 D = Direct gear
S Type of top gear
 S = Overdrive gear
300 Max. input torque (Nm)
G = Getrag

 J = Jatco
J Code letter of transmission manufacturer
 R = GMPT (General Motors Powertrain)
SMG Notes SMG = Sequential M gearbox/transmission
GS6-37BZ (new designation according to BMW Group Standard GS 90007)

G Transmission
S Transmission type
 - = Standard with manual gearshift
-  HP = Hydraulic planetary gear
 DKG= twin-clutch gearbox
 26 = D-transmission
 31 = C-transmission
 39 = F-transmission
 37 = H-transmission
37 Transmission type  53 = G-transmission
 17 = I-transmission
 47= J transmission SMG -7-speed
 45 = K transmission
 36= Transmission DKG
 B = Petrol gear ratio
B Gear set  D = Diesel gear ratio
 S= Sport gear ratio
 G = Getrag
Z Code letter of transmission manufacturer
Manual gearbox

S5D 200G Getrag B transmission (220/5)
2007 BMW 335i
S5D 200G Getrag B transmission (221/5) for M41 engine only

S5D 250G Getrag B transmission (220/5) Reinforced version
S5D 260Z ZF C-transmission (S5-31 D) for M51 engine only
S5D 280Z ZF C-transmission (S5-31)
S5D 310Z ZF C-transmission (S5-31) up to 9.95
S5D 320Z ZF C-transmission (S5-31) from 9.95 (reinforced version)
GS5S31BZ (SMG) ZF C transmission SMG
GS5-39DZ ZF F transmission
S6S 420G Getrag D-transmission (226/6)
S6S 420G (SMG) Getrag D transmission SMG
S6S 560G Getrag E-transmission (286/6)
GS6-37BZ ZF H-transmission
GS6S37BZ (SMG) ZF H-transmission
GS6-37DZ ZF H-transmission
GS6-37BG Getrag H-transmission
GS6-53BZ ZF G-transmission
GS6-53DZ ZF G-transmission
GS6-17BG Getrag I-transmission
GS6-17DG Getrag I-transmission
GS7S47BG (SMG) Getrag J-transmission (247) SMG -7-gear
GS7D36SG Getrag DKG (436) DKG -7-gear
GS6-45BZ ZF K transmission
GS6-45DZ ZF K transmission
Automatic transmission

A4S 200R General Motors Powertrain GM4
A4S 270R General Motors Powertrain THM-R1w Transmission wide-stepped
A4S 310R General Motors Powertrain THM-R1
A5S 300J Jatco Jatco
A5S 310Z ZF 5HP-18
A5S 325Z ZF 5HP-19
A5S 440Z ZF 5HP-24
A5S 560Z ZF 5HP-30
A5S 360R / 390R GM GM5
GA6HP19Z ZF 6HP19
GA6HP26Z ZF 6HP26
GA6HP32Z ZF 6HP32
GA6L45R GM GM6
GA8HP45Z ZF 8HP45
2007 BMW 335i
GA8HP70Z ZF 8HP70
GA8P70H ZF 8P70 Hybrid
GA8HP90Z ZF 8HP90
GA7AHSCD Daimler AHS-C Hybrid
23... UNIVERSAL BMW TRANSMISSION TAKE-UP
 00 2 030
 23 4 050
NOTE:  The universal transmission bracket is introduced for the E60 AWD
 Suitable for manual and automatic transmissions
IMPORTANT: Front and rear supports (1) can be laterally adjusted by means of screws (2).
Carrier (3) of rear supports (1) can be longitudinally adjusted by means of
screw.
Supports must be adapted in length and width to the transmission.
Fig. 29: Pushing Special Tool Onto Drive Shaft

IMPORTANT: Transmission must be secured with tensioning strap (1).

2007 BMW 335i
Fig. 30: Inserting Screw Into Special Tool (23 3 200)

23..... UNIVERSAL TRANSMISSION RETAINING BRIDGE
 00 1 450
 24 0 200
NOTE:  The transmission retaining bridge 24 0 200 is suitable for both manual and
automatic transmissions.
IMPORTANT: Adapters and spindles must be adapted for positive locking to the
transmission.
(Risk of injury)
Adapt adapters (1) and spindle with thrust piece (3) to transmission.
Adapt length with slide (2).
Screw in spindle (4).
IMPORTANT: Before mounting on assembly stand 00 1 450 , check retaining bridge for
secure seating.
2007 BMW 335i
Fig. 31: Pushing Radial Shaft Seal Onto Drive Shaft

HOUSING WITH COVER

23 11 615 REPLACING GUIDE TUBE FOR CLUTCH RELEASE UNIT (GS6-53BZ/DZ)
NOTE: (transmission removed)
 Remove clutch release bearing and release lever from guide tube. See 2151500 REMOVING AND
INSTALLING OR REPLACING CLUTCH RELEASE BEARING/LEVER (E90) , 21 51 500
(E90/E91) or 21 51 500 REMOVING AND INSTALLING OR REPLACING CLUTCH RELEASE
BEARING/LEVER (E92/E93) .
Release screws.
Remove guide tube (1).
Installation
Clean thread.
Install screws with Loctite 243.

2007 BMW 335i
Fig. 32: Releasing Collar Nut Using Special Tool (23 2 320)
NOTE: Remove sticker (1) and adhesive with a suitable solvent.
Fig. 33: Detaching Output Flange Using Special Tool And Adapter Plate From Output Shaft
BEARING IN HOUSING, SEALING RING

23 12 510 REPLACING RADIAL SHAFT SEAL FOR DRIVE SHAFT (GS6-53BZ/DZ)
 23 3 200
 23 3 220
2007 BMW 335i

Use only approved transmission oil . See MANUAL TRANSMISSION -
OPERATING FLUIDS .
 Remove clutch release unit and release lever from guide tube. See 2151500 REMOVING AND
INSTALLING OR REPLACING CLUTCH RELEASE BEARING/LEVER (E90) , 21 51 500
(E90/E91) or 21 51 500 REMOVING AND INSTALLING OR REPLACING CLUTCH RELEASE
BEARING/LEVER (E92/E93) .
Release screws.
Remove guide tube (1).
Installation:
Clean guide tube.
Do not grease guide tube.
Fig. 34: Sliding Special Tool (23 3 210) Over Output Shaft
Release screw on special tool 23 3 200 .

2007 BMW 335i
Push special tool onto drive shaft and screw into sealing ring.
Fig. 35: Inserting Screw Into Special Tool (23 3 210)

Insert screw into special tool 23 3 200 again and continue turning until sealing ring is pulled out of transmission
housing.
Fig. 36: Driving In Radial Seal Using Special Tool

Installation:
Coat sealing lips of radial seal with gear oil.
Push radial shaft seal (1) onto drive shaft up to housing.
Drive in radial shaft seal (1) as far as it will go with special tool 23 3 220 and plastic hammer.
2007 BMW 335i
Fig. 37: Sliding Locking Ring Towards Rear

23 12 059 REPLACING RADIAL SHAFT SEAL FOR OUTPUT SHAFT (GS6-53BZ/DZ)
 23 0 020
 23 0 200
 23 2 320
 23 3 210
 23 3 230
 33 1 150
 33 1 154
OPERATING FLUIDS .
transmission.
 Unflange propeller shaft from transmission and tie up to one side.
Tasks are described in removing PROPELLER SHAFT .
Brace output flange with special tool 23 0 020 .

2007 BMW 335i
Release collar nut with special tool 23 2 320 .
Release E90, 91 M57T2, E60S85 with special tool 23 0 200 .
Installation:
Mark flange with thermo pin and heat to min. 80°- 100°.
WARNING: Scalding hazard! Fit flange wearing suitable protective gloves only!
IMPORTANT: Do not drive on flange.
Fig. 38: Pulling Out Radial Seal Using Special Tool (23 0 210)
Secure collar nut with Loctite 243.
 Loctite 243: BMW Parts Service.

 Tightening torque: 23 21 1AZ .
Detach output flange (1) with special tool 33 1 150 and adapter plate 33 1 154 from output shaft.
2007 BMW 335i
Fig. 39: Driving In Radial Seal With Special Tool (23 0 220)
Release screw on special tool 23 3 210 .
Slide special tool 23 3 210 over output shaft and screw into sealing ring firmly.

Insert screw into special tool 23 3 210 again and continue turning until sealing ring is pulled out of transmission
housing.
If necessary, remove ring spring of sealing ring.

2007 BMW 335i

Installation:
Coat sealing lips of new radial seal with gear oil.
Drive in radial seal as far as it will go with special tool 23 3 230 and plastic hammer.
Fig. 42: Identifying Plug Connection And Transmission Mounting Bracket Bolts
23 12 089 REPLACING RADIAL SHAFT SEAL FOR SELECTOR SHAFT (GS6-53BZ/DZ)
 23 0 210
 23 0 220
2007 BMW 335i
OPERATING FLUIDS .
transmission.
 Shift transmission into 2nd gear

 Unflange propeller shaft from transmission.
Tasks are described in removing PROPELLER SHAFT .
Lever retaining ring (1) out of groove with a small screwdriver.
Slide locking ring (1) towards rear.
Drive out cylinder pin (2).
Fig. 43: Driving Hole Into Sealing Cap Using Suitable Tool
Screw in special tool 23 0 210 until it is firmly connected with radial seal (1).
Pull out radial seal with special tool 23 0 210 .

2007 BMW 335i
Fig. 44: Screwing Special Tool (23 0 490) Into Sealing Cap
Coat sealing lips of radial seal and selector shaft with transmission oil.
Drive in radial seal with special tool 23 0 220 .
Fig. 45: Identifying Sealing Cap

ELECTRICAL ADD-ON PARTS

23 14... REPLACING REVERSING LIGHT SWITCH

2007 BMW 335i

(E92/E93) .
Only transmissions GS6-17DG/BG and GS6-37DG/BG
Disconnect plug connection (1) on reverse gear switch.
Remove reverse gear switch.
Fig. 46: Driving Sealing Cap Using Special Tool (23 0 330)
Only transmission GS6-53DG/BG

2007 BMW 335i
Fig. 47: Identifying Rear Supports, Screws And Carrier

Only transmission GS6-45DZ/BZ
23 14 550 REMOVING/REPLACING ZERO-GEAR SENSOR
IMPORTANT: After installing the zero-gear sensor, it is necessary to teach in the position of
the zero-gear sensor again.
2007 BMW 335i
Calibration is carried out using the BMW Diagnosis System "Service

Function" (Learn/record zero-gear sensor).
 Lower transmission
Tasks are described in Removing transmission.
Disconnect plug connection (1) on zero gear sensor.
Remove zero gear sensor.
Installation note:
Replace screws (2).
Fig. 49: Identifying Adapters, Slide, Thrust Piece And Spindle

2007 BMW 335i
SUSPENSION Rear axle - Repair Instructions
SUSPENSION
Rear axle - Repair Instructions
GENERAL
33... REAR AXLE LAYOUT
Fig. 1: Rear Axle Components And Assembly

Facts:
2007 BMW 335i
E32, E34, E38, E39: In the case of rear spring struts with ride-height control, there is always a slight oil spillage
on the piston rod. These spring struts are permitted to be wet with oil over a maximum of half the shock
absorber length on the outer tube, i.e. they are permitted to "sweat".
Consequence:
Procedure:
33 00... INSTRUCTIONS (CHASSIS COMPONENTS MADE OF ALUMINIUM)
Due to the chemical and corrosion characteristics of aluminium, always comply with the following points when
handling aluminium components:
 Do not bring into contact with battery acid!

 Do not clean with wire brushes made of brass or iron! Always use wire brushes with stainless steel
bristles!
 Do not expose to flying sparks when grinding/separating! Cover components!
 Do not strike with steel welding splashes! Cover components!
 Do not expose to temperatures > 80°C, even for brief periods! Temperatures in paint facilities do not have
the same impact
NOTE: Damaged threads in the frame side member may be repaired with Helicoil
thread inserts. Comply with the procedure described in the example.
2007 BMW 335i
Fig. 2: Helicoil Thread

33 00... REAR AXLE: WHEEL/CHASSIS ALIGNMENT CHECK MUST BE CARRIED OUT AFTER
THE FOLLOWING WORK
Fig. 3: Rear Axle Components And Assembly

A wheel/chassis alignment check must be carried out after the following work:
2007 BMW 335i

 Camber arm to rear axle carrier / wheel carrier
 Trailing arm to rear axle carrier / wheel carrier
 Guide arm to rear axle carrier
 Toe arm to rear axle carrier / wheel carrier
 Control arm to rear axle carrier

1. Rear axle carrier
2. Camber arm / rubber mount / ball joint
3. Trailing arm / rubber mount
4. Guide arm
5. Wheel carrier / rubber mount / ball joint
6. Toe arm
7. Control arm
FINAL DRIVE
33 10... OVERVIEW OF REAR DIFFERENTIAL/OUTPUT SHAFTS
Fig. 4: Rear Differential/Output Shafts Components And Assembly

00 11... CHECKING/TOPPING UP OIL LEVEL IN REAR AXLE FINAL DRIVE

2007 BMW 335i
To avoid serious damage to the rear differential, it is essential to use only

APPROVED GEAR OILS in the differential.
Undo oil filler plug (1).
Check oil level.
If necessary, pour in rear differential oil up to lower edge of opening for oil filler plug (1).
Installation note:
Replace oil filler plug (1).
For tightening torque refer to 2AZ in 33 11 REAR DIFFERENTIAL CASE WITH COVER .
Fig. 5: Identifying Rear Differential Oil Filler Plug

33 10... REAR DIFFERENTIAL: ASSIGNMENT TO MODEL SERIES
REAR DIFFERENTIAL: ASSIGNMENT TO MODEL SERIES

Model series Engine Rear differential Remark
E90 N46, N45, N52 (323i) 168L
M47T2, M57T2, N47, 188L / 188LW
N51, N52, N53
M57T2 (330d, 335d), 215L / 215LW
N54 Manual
transmission: M57T2
(325d, 330xd)
E91 N43, N46, N52 (323i) 168L
2007 BMW 335i
M47T2, M57T2, N52, 188L / 188LW

N53
M57T2 (330d, 335d), 215L / 215LW
N54 Manual
transmission: M57T2
(325d, 330xd)
E92 N43, N46, 168L
M57T2, N47, N51, N52, 188L / 188LW
N53
M57T2 (330d, 335d), 215L / 215LW
N54 Manual
transmission: M57T2
(325d, 330xd)
S65 215 with lock
E93 N43, N46 168L
M57T2, N51, N52, N53 188L / 188LW
M57T2 (330d), N54 215L / 215LW
L Light-running
LW Light-running, efficiency-optimized
33 10... REMOVING AND INSTALLING/REPLACING VIBRATION DAMPER
Variant A:
Release screw (1).
For tightening torque refer to 33 17 2AZ in 33 17 REAR AXLE DIFFERENTIAL MOUNTINGS .
Remove vibration damper (2).
Fig. 6: Vibration Damper And Screw

2007 BMW 335i
Variant B:
Release bolt (1) and remove vibration damper (2).
Fig. 7: Vibration Damper And Bolt

Variant C:
NOTE: Removal depicted on left vibration damper.
Release bolt (1) and remove vibration damper (2).
Fig. 8: Vibration Damper And Bolt

2007 BMW 335i
Variant D (E93):
Remove left and right tension struts (on rear axle).
Release bolts (1) and remove vibration damper (2).
For tightening torque refer to 33 33 3AZ in 33 33 REAR AXLE SUSPENSION .
33 10 010 REMOVING AND INSTALLING/REPLACING REAR DIFFERENTIAL
 33 4 420
IMPORTANT: Use only approved rear differential oils !
NOTE: The following sequence was created using the E87 with N45 as an example.
Differences in detail (e.g. due to vibration damper) in other engines are
possible.
 Remove propeller shaft from rear differential

 Remove output shaft from rear differential at both ends and tie back
IMPORTANT: Observe gap between special tool 33 4 420 and dust plates.
To avoid grinding noises, make sure the dust plates are not damaged (e.g.
bent).
Support rear differential with workshop jack and special tool 33 4 420.
Release screws (1).
Release nut (2) and remove screw towards rear.
Slowly lower workshop jack and remove rear differential towards rear.
IMPORTANT: Adhere to the following installation sequence in order to prevent distortion of

the rear differential during installation and thereby avoid potential complaints
about noise.
2007 BMW 335i
Fig. 9: Bolts, Nut And Special Tool (33 4 420)

1. Install rear differential with workshop jack and special tool 33 4 420.
2. Insert bolts (1) (do not tighten down)
3. Insert screw from rear and replace nut (2) (do not tighten down)
4. Lower workshop jack
5. Tighten screws (1)
6. Tighten nut (2)
Fig. 10: Bolts, Nut And Special Tool (33 4 420)

2007 BMW 335i
After installation:
 Check rear differential oil level , correct if necessary.
FINAL DRIVE WITH COVER

33 11... REPLACING REAR COVER GASKET ON REAR DIFFERENTIAL (168L)
IMPORTANT: To avoid leaks from the rear differential cover, do not use a paper gasket in
cars with liquid gaskets!
To prevent the differential oil from foaming over, make sure that no remnants
of the liquid gasket are pressed into the rear differential housing.
Release screws (1).
For tightening torque refer to (M10x60) 33 11 1AZ in 33 11 REAR DIFFERENTIAL CASE WITH
COVER .
Unscrew screws (2).
COVER .
Remove cover.
If necessary, remove remnants of liquid gasket with scraper.
Clean sealing face on cover and rear differential.
Installation:
If a paper gasket was fitted, a paper or liquid gasket can be used.
The liquid gasket can be found in Main Group 33 in the Electronic Parts Catalogue.
2007 BMW 335i
Fig. 11: Rear Cover Gasket Screws

33 11... REPLACING REAR COVER GASKET ON REAR DIFFERENTIAL (188L / 188LW)
Release screws (1).
COVER .
Unscrew screws (2).
COVER .
Remove cover.
Installation:
2007 BMW 335i

33 11... REPLACING REAR COVER GASKET ON REAR DIFFERENTIAL (215L / 215LW)
Unscrew screws (1) and (2).
COVER .
COVER .
Remove cover.
Installation:
2007 BMW 335i

33 11 021 REPLACING RADIAL SHAFT SEAL FOR INPUT FLANGE ON FINAL DRIVE
 00 5 010
 00 5 500
 23 0 020
 23 1 300
 23 1 302
 23 1 303
 31 2 101
 31 2 102
 31 2 103
 31 2 104
 33 1 150
 33 1 341
 33 3 390
 33 3 440
 33 3 470
 33 3 480
 33 3 490
IMPORTANT: Use only approved gear oils.
Failure to comply with this instruction will result in serious damage to the rear
differential!
2007 BMW 335i
 Remove propeller shaft from rear differential drive flange , remove complete propeller shaft if
necessary
Removing drive flange:
Lift out retaining plate.
Mark position of collar nut (1) on drive shaft with peening tool.
Fig. 14: Mark Position And Drive Shaft Collar Nut

Brace drive flange with special tool 23 0 020 and release collar nut.

NOTE: Read and comply with document "Rear differential: Assignment to model
series".
2007 BMW 335i
215L:
Remove drive flange with special tools 31 2 101, 31 2 102, 31 2 103 / 31 2 104.
Fig. 16: Special Tools (31 2 101), (31 2 103), (31 2 104), (31 2 102) And Removal Directions
168L, 188L:
Remove drive flange with special tool 33 1 150.
Fig. 17: Bolts, Special Tool (33 1 150) And Removal Directions
Replacing shaft seal:
Withdraw shaft seal with special tool 00 5 010.

2007 BMW 335i

Drive in new shaft seal with following special tools (depending on rear differential) as far as it will go.
 168L: Use special tools 00 5 500 and 33 3 390

Fig. 19: Special Tools (00 5 500), (33 3 440), (33 3 470) And (33 3 390)
Installing drive flange:
Coat sealing lips of shaft seal and sealing surface of drive flange with differential oil.
Fit drive flange.
Press on drive flange with special tools 23 1 300, 33 1 341 and 23 1 303, if necessary 23 1 302 until collar nut
can be screwed on.
2007 BMW 335i
IMPORTANT: Do not under any circumstances tighten down collar nut beyond marker points
in order to avoid damaging the clamping sleeve.
Tighten down collar nut (1) to point where marker points are aligned.
Fig. 21: Collar Nut And Alignment Marks

Drive in new retaining plate with following special tools (depending on rear differential) as far as it will go.
 168L, 188L: Use special tools 00 5 500 and 33 3 480

2007 BMW 335i
Fig. 22: Special Tools (00 5 500), (33 3 480) And (33 3 490)
After installation:
 Correct rear differential fluid level
33 11 091 REPLACING DRIVE FLANGE ON LEFT OR RIGHT OF REAR DIFFERENTIAL
WARNING: Risk of burning on the exhaust system!
IMPORTANT: When replacing the drive flange, you must also replace the shaft seal!
 Remove output shaft from rear differential and tie back
Using a suitable screwdriver and a hammer (acting as a rest), force drive flange (1) off rear differential.
Installation:
Replaced deformed or damaged dust plates.
Insert drive flange and rotate until spline on flange meshes with teeth on differential bevel gear.
Press drive flange in further until circlip locates with an audible click.
IMPORTANT: High installation forces indicate that the spline teeth on the drive
flange/differential bevel gear are damaged/deformed!
Check spline teeth, replaced damaged parts.
2007 BMW 335i
Fig. 23: Drive Flange

Install retaining ring (1).
Installation:
Clean shaft seal race on drive flange thoroughly.
Coat drive flange at contact face of shaft seal with approved rear differential oil.
Fig. 24: Retaining Ring

Replacement:
Replace shaft seal.
After installation:
 Check rear differential fluid level , correct if necessary

2007 BMW 335i
33 11 151 REPLACING SHAFT SEAL FOR DRIVE FLANGE LEFT OR RIGHT
 00 5 010
 00 5 500
 32 1 060
 33 1 308
 33 3 400
 33 4 240
 33 4 250
 33 5 030
 Remove drive flange from rear differential

 If necessary, press off dust cover
Withdraw shaft seal with special tools 00 5 010 and 32 1 060 / 33 1 308.
Coat housing plate flange and sealing lips of new shaft seal with approved rear differential oil.
Drive in new shaft seal as far as it will go with following special tool(s) (depending on rear
differential /outside diameter).
00 5 500 + 33 3 400: 168K/L - 78x44x10
00 5 500 + 33 4 240: 188K/L/LW - 90x44x10

2007 BMW 335i
00 5 500 + 33 4 250: 215K/L/LW, 220K to 230K - 100x50x10
33 5 030: 210, 215 with lock - 76x50x10
Fig. 26: Special Tools (33 4 240), (00 5 500), (33 4 240), (33 3 400), (33 5 030) And (33 4 250)
After installation:
 Correct gearbox oil level/change differential oil
33 11 271 REPLACING REAR COVER GASKET ON REAR DIFFERENTIAL
IMPORTANT: In event of oil loss, always check rear differential for traces of wear and
damage.
 Draw off rear differential oil

 Remove rear differential
NOTE: Read and comply with document "Rear differential: Assignment to model
series".
Select rear differential:
 168L
 188L / 188LW
 215L / 215LW
After installation:
2007 BMW 335i
 Add rear differential oil
FINAL DRIVE MOUNTING

33 17... REPLACING RUBBER MOUNT
 33 4 281
 33 4 282
 33 4 283
 33 4 284
 33 4 465
 33 4 466
Withdrawing rubber mount:
Withdraw rubber mount with special tools 33 4 282, 33 4 281, 33 4 466, 33 4 465 and a nut (1).
Fig. 27: Nut, Special Tools (33 4 282), (33 4 281), (33 4 465), (33 4 466) And Removal Direction
Installing rubber mount:
IMPORTANT: Coat bearing bushing in rear axle carrier and new rubber mount with Circolight.
Align rubber mount by way of elongated hole (1) to vehicle transversal direction.
2007 BMW 335i
Fig. 28: Elongated Hole

Insert rubber mount (1) in special tool 33 4 283.
Align rubber mount (1) by way of elongated hole to vehicle transversal direction.
Draw in rubber mount (1) with special tools 33 4 282, 33 4 283, 33 4 284, 33 4 466, 33 4 465 and nut (2) as far
as it will go.
Fig. 29: Rubber Mount, Nut, Special Tools (33 4 282), (33 4 283), (33 4 284), (33 4 466), (33 4 465) And
Installation Direction
33 17... REPLACING RUBBER MOUNT (WITH HYDRAULIC DAMPING)
 33 4 281
 33 4 351
 33 4 357
 33 4 358
 33 4 465
2007 BMW 335i
 33 4 466
Withdrawing rubber mount:
Pull out rubber mount with special tools 33 4 351, 33 4 281, 33 4 466 and 33 4 465.
Installing rubber mount:
IMPORTANT: Coat bearing bushing in rear axle carrier and new rubber mount with Circolight.
Draw in rubber mount with end shown from front into rear axle carrier. In so doing, make sure that the arrows
on the rubber mount point upwards.
Fig. 31: Rubber Mount

Align special tool 33 4 358 by means of openings to rubber mount.

2007 BMW 335i

Draw in rubber mount (1) with special tools 33 4 357, 33 4 358, 33 4 466 and 33 4 465 as far as it will go.
Fig. 33: Rubber Mount, Special Tools (33 4 357), (33 4 358), (33 4 465) And (33 4 466)
33 17 004 REPLACING ALL FRONT RUBBER MOUNTS FOR REAR DIFFERENTIAL MOUNTING
 33 3 312
 33 4 161
 33 4 162
 33 4 166
 33 4 311
 33 4 312
 33 4 465
2007 BMW 335i
 33 4 466
Withdrawing front rubber mount:
Withdraw front rubber mount with special tools 33 3 312, 33 4 161, 33 4 162, 33 4 466 and 33 4 465.
NOTE: Milled recess of special tool 33 4 161 must point upwards to rear axle carrier.
Fig. 34: Special Tools (33 4 161), (33 3 312), (33 4 466), (33 4 465) And (33 4 162)
Installing front rubber mount:
IMPORTANT: Coat bearing bushing in rear axle carrier and front rubber mount with
Circolight.
Front rubber mount must be aligned by way of slots (1) to vehicle transversal direction.
2007 BMW 335i
Fig. 35: Front Rubber Mount Aligning Slots

Insert front rubber mount in special tool 33 4 311.
Align front rubber mount so that side slots (1) line up with marking (M) on tool.
Fig. 36: Front Rubber Mount Aligning Side Slots, Marking And Special Tool (33 4 311)
Draw in front rubber mount with special tools 33 4 465, 33 4 466, 33 4 166, 33 4 311 and 33 4 312 as far as it
will go.
2007 BMW 335i
Fig. 37: Marking, Special Tools (33 4 465), (33 4 466), (33 4 312), (33 4 311) And (33 4 166)
33 17 005 REPLACING RUBBER MOUNT FOR REAR DIFFERENTIAL MOUNTING AT REAR
IMPORTANT: Rubber mounts must not be mixed up!
A. = Remove rubber mount

B. = Remove rubber mount (with hydraulic damping)
Fig. 38: Rubber Mount And Rubber Mount (With Hydraulic Damping)
OUTPUT SHAFTS
2007 BMW 335i
33 21... PRESSING OUTPUT SHAFT OUT OF DRIVE FLANGE AND DRAWING IN (OUTPUT
SHAFT REMOVED FROM REAR DIFFERENTIAL)
 33 2 111
 33 2 115
 33 2 116
 33 2 117
 33 2 118
 33 2 119
 33 2 160
 33 2 201
 33 2 202
 33 2 203
 33 2 205
 33 2 206
 33 2 207
 33 5 070
It is not permitted to use the impact screwdriver to press out and draw in
the output shaft.
To avoid damaging the output shaft and adjoining parts, it is essential during
the pressing-out process to repeatedly check and if necessary correct the
position of the output shaft.
IMPORTANT: To avoid damaging the dust sleeve, use special tool 33 2 160 to press out and
draw in the output shaft after removing the brake disk.
NOTE: Rounded inside edge of special tool 33 2 160 must point to drive flange.
2007 BMW 335i

Special tool 33 2 200:
Secure output shaft against falling out.
Screw on special tool 33 2 203, 33 2 207 and 33 2 201 with all wheel studs to drive flange.
Press output shaft out of drive flange; in so doing, grip basic body 33 2 201 with special tools 33 2 202 and 33 5
070.
IMPORTANT: No oil permitted on shaft journal thread!
Lightly oil spline teeth of output shaft.
Insert output shaft into drive flange.

2007 BMW 335i
Screw special tool 33 2 205 / 33 2 206 onto output shaft.

Mount special tool 33 2 201 with three wheel studs to drive flange.
Draw in output shaft with special tool 33 2 205 up to stop; in so doing, grip basic body 33 2 201 with special
tools 33 2 202 and 33 5 070.
Special tool 33 2 100:
Secure output shaft against falling out.
Screw on special tool 33 2 111, 33 2 117 and 33 2 116 with all wheel studs to drive flange.
Press output shaft out of drive flange; in so doing, grip basic body 33 2 116 with special tools 33 2 202 and 33 5
070.
2007 BMW 335i
Fig. 43: Special Tools (33 2 111) (33 2 116), (33 5 070), (33 2 202) And (33 2 117)
IMPORTANT: No oil permitted on shaft journal thread!
Lightly oil spline teeth of output shaft.
Insert output shaft into drive flange.
Screw special tool 33 2 118 / 33 2 119 onto output shaft.

Mount special tool 33 2 116 with three wheel studs to drive flange.
Draw in output shaft with special tool 33 2 115 up to stop; in so doing, grip basic body 33 2 116 with special
tools 33 2 202 and 33 5 070.
2007 BMW 335i
33 21... RIBBED TEETH
IMPORTANT: Bolts with ribbed teeth must be replaced after they have been released!
Fig. 46: Bolts With Ribbed Teeth

33 21 001 REMOVING AND INSTALLING OR REPLACING LEFT OUTPUT SHAFT
WARNING: Risk of burning on the exhaust system!
 Remove tension strut if necessary

 Lower exhaust system in rear area
2007 BMW 335i
The subsequent procedure is described in the document "Removing and installing or replacing right output
shaft".
33 21 002 REMOVING AND INSTALLING / REPLACING RIGHT OUTPUT SHAFT
Remove rear wheel.
IMPORTANT: Expand turning lock sufficiently to avoid damaging thread when releasing
collar nut.
Release collar nut (1), activate handbrake for this purpose.
Installation:
Replace collar nut, oil collar nut/wheel bearing contact surface only and tighten down.
No oil permitted on thread of shaft journal or collar nut.
For tightening torque refer to 33 41 1AZ in 33 41 WHEEL BEARINGS .
Secure collar nut by positive peening on flat areas of output shaft.
Remove tension strut if necessary
Fig. 47: Collar Nut

Release bolts and remove with washers (1).
Press output shaft off drive flange using a suitable tool; if necessary, raise wheel carrier with workshop jack
approx. 20 mm.
Installation:
2007 BMW 335i
Before installing output shaft, make sure that drive flange is fully engaged in rear differential.
Replace bolts and washers (1).
For tightening torque refer to 33 21 1AZ in 33 21 OUTPUT SHAFT .
Press output shaft out of drive flange and remove towards center of vehicle.
Fig. 48: Drive Flange Washers And Bolts

After installation:
 Check that output shaft is correctly seated in rear differential.
33 21 035 REPLACING GAITER ON LEFT OUTPUT SHAFT (MODIFIED SEALING CAP

VERSION)
 21 2 120
 26 1 110
 33 2 100
 Remove output shaft
Removing inner gaiter:
Clean output shaft and clamp with a cloth in vice.

2007 BMW 335i
Using a suitable tool, force gaiter cap (2) off joint or sealing cover.
Fig. 49: Hose Clip And Gaiter Cap

Push back gaiter with cap.
Make sure that joint does not fall apart.
Clamp joint (1) in vice.
Using a suitable tool, force sealing cover (2) off joint (1).
Fig. 50: Sealing Cover And Joint

IMPORTANT: Mark positions in relation to each other of ball hub, ball cage and joint at ends.
2007 BMW 335i
NOTE: If the joint falls apart, it can only be reassembled correctly with the aid of the
markings.
Fig. 51: Mark Positions Of Ball Hub, Ball Cage And Joint At Ends
Remove circlip (1).
Fig. 52: Circlip

Grip output shaft.
Using special tool 26 1 110 and a suitable tool (for hollow shaft 21 2 120), press output shaft out of joint (1).
Clean joint (1) carefully.
NOTE: All traces off old grease must be removed.
Detach gaiter from output shaft.

2007 BMW 335i
Fig. 53: Joint, Special Tools (26 1 110) And (21 2 120)
Removing and installing outer gaiter:
Release hose clamps (1, 3) and detach gaiter (2) from output shaft.
Clean joint and output shaft carefully.
NOTE: All traces off old grease must be removed.
Check joint for damage; if necessary, replace output shaft.
Fill joint with propeller shaft grease.
Fit gaiter (2) on bellows and secure with hose clamps (1, 3).
Fig. 54: Hose Clamps And Output Shaft Gaiter

2007 BMW 335i
Installing inner gaiter:
Push gaiter with cap onto output shaft (1).
Mount special tool 33 2 100 with corresponding shell inserts on output shaft (1).
Press joint (2) over bearing inner race onto output shaft.
Fig. 55: Output Shaft, Joint And Special Tool (33 2 100)
Install new circlip (1).
Fig. 56: Circlip

IMPORTANT: Keep sealing faces of cap and joint (on both sides) clean and free from grease.
Fill joint at both ends with high-temperature grease.

2007 BMW 335i
Fig. 57: Sealing Faces Of Cap And Joint

Do not install gaiter with cap and sealing cover on joint without shims.
Apply a thin coating of sealing compound to sealing faces of sealing cover and cap.
Install sealing cover (1) with two bolts, shims and nuts on joint.
Fig. 58: Sealing Cover

Install cap (1) with two bolts, shims and nuts on joint.
Fit hose clamp (2).

2007 BMW 335i
Fig. 59: Cap And Hose Clamp

33 21 036 REPLACING GAITER ON RIGHT OUTPUT SHAFT
Procedure is described in the document "Replacing gaiter on left output shaft".
REAR SUB-FRAME
33 31... OVERVIEW OF REAR AXLE CARRIER WITH RUBBER MOUNTS
2007 BMW 335i
Fig. 60: Rear Axle Carrier With Rubber Mounts Components And Assembly
33 31 000 REMOVING AND INSTALLING COMPLETE REAR AXLE CARRIER
 00 2 040
 33 4 491
 33 4 492
Mount securing fixture for vehicle on lifting platform to prevent the

vehicle from slipping off or tilting down.
 Remove rear wheels

2007 BMW 335i
 Remove propeller shaft

 Remove both rear coil springs
 Remove pulse generator on both sides from wheel carrier , unclip line from control arm and rear axle
carrier
 Disconnect plug connection from brake pad sensor, unclip line from control arm and rear axle carrier
 Disconnect plug connection from ride-height sensor and unclip line from rear axle carrier
 Disengage handbrake cable on both sides from expander lock and then remove from hanging hooks
 Remove shock absorber on both sides from camber arm rubber mount

Position an oil tray underneath to catch brake fluid.
Release banjo bolts (1), gripping brake hoses (2) at square head in the process.
Disconnect brake hoses (2) and seal off with plugs.
Installation:
Make sure brake hoses are laid without tension and with sufficient spacing to adjoining components.

2007 BMW 335i
Fig. 62: Brake Hoses And Banjo Bolts


Insert special tools 33 4 491 and 33 4 492 into corresponding receptacle of special tool 00 2 040.
Align special tool 00 2 040 to rear axle carrier.
If necessary, lower special tool 33 3 274.
Support rear axle carrier by raising special tool 00 2 040.

2007 BMW 335i
Remove tension struts.
Release screws (1) and swivel/remove stop plates (2) to one side.
Lower rear axle completely.
Installation:
First install tension struts and then tighten down bolts (1).
Fig. 64: Screws And Swivel/Remove Stop Plates

2007 BMW 335i
After installation:

33 31 011 REPLACING REAR AXLE CARRIER

 Remove complete rear axle carrier
Remove brake discs (disconnect brake hose from brake line).
Remove brake lines from rear axle carrier.
Remove stabilizer bar (remove stabilizer links from wheel carrier).
Remove ride-height sensor with holder from rear axle carrier .
E93: Remove vibration damper (variant D).
Fig. 65: Complete Rear Axle Carrier

Remove camber arm on both sides from rear axle carrier.
Remove toe arm on both sides from rear axle carrier.
Remove trailing arm on both sides from rear axle carrier.
Remove guide arm on both sides from rear axle carrier.

2007 BMW 335i
Remove control arm on both sides from rear axle carrier.
Remove wheel carrier on both sides with output shaft and all suspension arms.
Fig. 66: Complete Rear Axle Carrier

After installation:

 Perform chassis alignment check
33 31 503 LOWERING/RAISING REAR AXLE CARRIER
 00 2 040
 33 4 491
 33 4 492
Mount securing fixture for vehicle on lifting platform to prevent the

vehicle from slipping off or tilting down.
Scalding hazard!
This work may only be carried out on an exhaust system which has
cooled down.

2007 BMW 335i

 E91, E92, E93: Remove tension strut

Position an oil tray underneath to catch brake fluid.
Release banjo bolts (1), gripping brake hoses (2) at square head in the process.
Disconnect brake hoses (2) and seal off with plugs.
Installation:
Make sure brake hoses are laid without tension and with sufficient spacing to adjoining components.

2007 BMW 335i
Fig. 68: Brake Hoses And Banjo Bolts

Unclip cables for pulse generator and ride-height sensor/brake pad sensor on rear axle carrier at side.
Slacken nut (1).
Turn bracket (2) for exhaust system towards rear.
Unscrew heat shield.
Fig. 69: Bracket And Nut


2007 BMW 335i

Insert special tools 33 4 491 and 33 4 492 into corresponding receptacle of special tool 00 2 040.
Align special tool 00 2 040 to rear axle carrier.
If necessary, lower special tool 33 3 274.
Support rear axle carrier by raising special tool 00 2 040.
Remove tension struts.
Release screws (1) and swivel/remove stop plates (2) to one side.
Lower rear axle carrier.
Installation:
First install tension struts and then tighten down bolts (1).

2007 BMW 335i
Fig. 71: Identifying Screws And Swivel/Remove Stop Plates

After installation:
 Bleed brakes
CONTROL ARMS AND STRUT

33 32... OVERVIEW OF STEERING LINKS
2007 BMW 335i
Fig. 72: Steering Links Components And Assembly

33 32 021 REPLACING LEFT OR RIGHT TRAILING ARM
NOTE: If the trailing arm is detached from the rear axle carrier/wheel carrier, it is
necessary after reinstallation to carry out a wheel/chassis alignment check.
Release nuts (1, 3).
Unscrew bolts.
Remove trailing arm (2) downwards.
Installation:
Note insertion direction of bolts.

2007 BMW 335i
For tightening torque refer to (on rear axle carrier) 33 32 1AZ in 33 32 CONTROL ARMS AND STRUTS .
For tightening torque refer to (on wheel carrier) 33 32 2AZ in 33 32 CONTROL ARMS AND STRUTS .
Fig. 73: Trailing Arm, Bolts, Nuts And Removal Directions

After installation:
33 32 031 REPLACING RUBBER MOUNT FOR TRAILING ARM IN WHEEL CARRIER
 33 4 450
 33 4 451
 33 4 452
 33 4 453
 33 4 454
 33 4 465
 33 4 466
 33 4 472
 33 4 473
 33 4 474
 33 4 475
 Remove trailing arm from wheel carrier

2007 BMW 335i
Removing rubber mount:
Pull out rubber mount with special tools 33 4 465, 33 4 466, 33 4 475, 33 4 474 and 33 4 472.
Installing new rubber mount:
Insert rubber mount with spray-on points facing upwards in special tools 33 4 451, 33 4 452, 33 4 454, 33 4 453
and pull together.
Insert rubber mount in special tool 33 4 473.
IMPORTANT: Spray-on points of rubber mount must point to rear!
Align rubber mount by way of slot (1) at an angle to wheel carrier.

2007 BMW 335i
Fig. 76: Aligning Rubber Mount By Way Of Slot At An Angle To Wheel Carrier
Draw rubber mount with special tools 33 4 465, 33 4 466, 33 4 475, 33 4 474 and 33 4 473 a little into wheel
carrier.
Remove special tool 33 4 450 and draw in rubber mount as far as it will go.
After installation:
 Carry out wheel/chassis alignment check
33 32 035 REPLACING A RUBBER MOUNT FOR TRAILING ARM IN REAR AXLE CARRIER
 33 4 450
2007 BMW 335i
 33 4 451
 33 4 452
 33 4 453
 33 4 454
 33 4 465
 33 4 466
 33 4 471
 33 4 472
 33 4 474
 33 4 475
 Remove trailing arm from rear axle carrier
Mark installation position of rubber mount by way of slot to rear axle carrier.
If necessary, release knurled screws 33 4 452 and pull off mounting 33 4 455 with spring steel 33 4 456.
Insert rubber mount with spray-on points facing upwards in special tools 33 4 451, 33 4 452, 33 4 454, 33 4 453
and pull together.
2007 BMW 335i
IMPORTANT: Coat rubber mount with Loctite 638 prior to installation.
Spray-on points of rubber mount must point to rear!
All models except M3:
Align rubber mount by way of slot (1) at an angle to rear axle carrier.
Fig. 80: Aligning Rubber Mount By Way Of Slot At An Angle To Rear Axle Carrier
M3:
Align rubber mount by way of slot (1) at an angle to rear axle carrier.
2007 BMW 335i
Fig. 81: Aligning Rubber Mount By Way Of Slot At An Angle To Rear Axle Carrier
Align rubber mount by way of slot to marking on rear axle carrier.
Draw rubber mount a little into rear axle carrier with special tools 33 4 471, 33 4 474, 33 4 475, 33 4 466 and 33
4 465.
Apply a thin coating of Loctite 638 to new rubber mount.
Draw in rubber mount as far as it will go.
After installation:
 Carry out wheel/chassis alignment check

2007 BMW 335i
33 32 071 REPLACING ONE UPPER CONTROL ARM
NOTE: If the control arm is detached from the rear axle carrier, it is necessary after
 Remove rear wheel .
Release screw (1).
Installation:
If necessary, raise brake disk in drive flange area with workshop jack.
Replace screw.
For tightening torque refer to 33 32 6AZ in 33 32 CONTROL ARMS AND STRUTS .
Fig. 83: Screw

IMPORTANT: Make sure during installation that in the connection area to the wheel carrier
the tapered end of the bearing bushing (of the rubber mount) points in the
direction of the wheel carrier.
2007 BMW 335i
Fig. 84: Identifying Bearing Bushing

Release nut (1) and remove screw towards front.
Remove lines (3) for pulse generator/brake pad sensor with retaining clips from control arm.
Remove control arm (2).
Installation:
Bolt head points in direction of travel.
Fig. 85: Control Arm, Nut, Line Holder And Removal Direction
2007 BMW 335i
After installation:
33 32 091 REPLACING A CONTROL ARM
NOTE: If the guide arm is detached from the rear axle carrier, it is necessary after
 Remove rear wheel

 Remove stabilizer links on both sides from stabilizer and rotate stabilizer in upward direction
Release screw.
Installation:
If necessary, raise wheel carrier in area of brake caliper by hand.
Replace screw.
Fig. 86: Bolt

IMPORTANT: Make sure during installation that in the connection area to the wheel carrier
the tapered end of the bearing bushing (of the rubber mount) points in the
direction of the wheel carrier.
2007 BMW 335i
Fig. 87: Bearing Bushing

NOTE: On the M3 a ball joint is fitted in the guide arm.
Slacken nut (1).
Unscrew bolt towards rear and remove guide arm (2).
Installation:
Bolt head must point to rear.
Fig. 88: Guide Arm, Nut And Removal Direction

2007 BMW 335i
After installation:
33 32 125 REPLACING A BALL JOINT IN LOWER STEERING KNUCKLE/WHEEL CARRIER
 33 4 465
 33 4 466
 33 4 474
 33 4 475
 33 4 481
 33 4 482
 Remove coil spring at rear

 If necessary, remove jointed rod of ride-height sensor from camber arm bracket
 Remove rear shock absorber from rubber mount
 Remove camber arm from wheel carrier
 Remove trailing arm from wheel carrier
Pull out ball joint with special tools 33 4 465, 33 4 466, 33 4 475, 33 4 474 and 33 4 482.
Fig. 89: Special Tools (33 4 465), (33 4 475),(33 4 474), (33 4 482) And (33 4 466)
Installation:
Draw in new ball joint with special tools 33 4 481, 33 4 474, 33 4 475, 33 4 466 and 33 4 465 as far as it will
2007 BMW 335i
go.
After installation:
33 32 131 REMOVING AND INSTALLING / REPLACING A STEERING KNUCKLE / WHEEL

CARRIER

 Remove brake disk
 Replacement only: drive out drive flange for rear axle shaft
 Disconnect handbrake Bowden cable from expander lock
 Remove pulse generator from wheel carrier
 Remove coil spring
 Remove rubber mount/shock absorber on camber arm
Secure wheel carrier against falling out.
Remove stabilizer link from wheel carrier.
Remove trailing arm from wheel carrier.
Remove guide arm from wheel carrier.
Remove toe arm from wheel carrier.

2007 BMW 335i
Remove upper control arm from wheel carrier.
Remove camber arm from wheel carrier.
Remove wheel carrier.
Fig. 91: Identifying Wheel Carrier

Replacement:
 Modify or replace handbrake shoes

 Modify or replace expander lock
 Modify or replace brake carrier/brake guard plate
After installation:
33 32 160 REMOVING AND INSTALLING/REPLACING COMPRESSION STRUT FOR REAR AXLE

CARRIER
IMPORTANT: Observe safety instructions for raising the vehicle.
Driving without compression struts is not permitted!
Risk of damage!
The rear axle carrier must be supported at the front if both compression struts
have to be replaced!
2007 BMW 335i
 Remove underbody cover
Release screw (1).
Installation:
Replace screws.
Release screw (4) and remove compression strut (3).
Installation:
Fig. 92: Compression Struts And Screws

33 32 165 REMOVING AND INSTALLING/REPLACING TENSION STRUT
IMPORTANT: Observe safety instructions for raising the vehicle.
Release screws (1, 3).

2007 BMW 335i
Installation:
For tightening torque refer to 33 32 11AZ (to body) in 33 32 CONTROL ARMS AND STRUTS .
For tightening torque refer to 33 32 12AZ (to compression strut) in 33 32 CONTROL ARMS AND STRUTS .
Fig. 93: Tension Strut And Screws

33 32 180 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT TOE ARM
NOTE: If the toe arm is detached from the rear axle carrier/wheel carrier, it is necessary
after reinstallation to carry out a wheel/chassis alignment check .
 Remove rear wheel.
Mark position of eccentric screw to rear axle carrier.

2007 BMW 335i
Fig. 94: Mark Position Of Eccentric Screw

Release screw.
Installation:
If necessary, turn toe arm by hand.
Fig. 95: Bolts

Release nut (1) and remove eccentric washer (2).
Unscrew eccentric bolt towards front and remove toe arm (3).
Installation:
2007 BMW 335i
Bolt head points in direction of travel.
Reinstall eccentric washer.
Align eccentric screw by means of marking to rear axle carrier.
Fig. 96: Eccentric Washer, Toe Arm And Nut

After installation:

REAR AXLE) (UP TO 03/2007)
See REMOVING AND INSTALLING/REPLACING REAR MIDDLE TENSION STRUT (UP TO

03/2007) .

REAR AXLE) (FROM 03/2007)
See REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT TRAILING LINK (ON REAR
AXLE) (FROM 03/2007) .
33 32 190 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT CAMBER ARM

2007 BMW 335i
cooled down.
NOTE: If the camber arm is detached from the rear axle carrier/wheel carrier, it is
necessary after reinstallation to carry out a wheel/chassis alignment check .
 Remove coil spring at rear

 Remove rubber mount for shock absorber mounting on camber arm
 Remove jointed rod of ride-height sensor from camber arm bracket
Support wheel carrier with workshop jack.
Mark position of eccentric screw (1) to camber arm.
Replacement only: Carry over marking from old part to new part.
Release nut (2) and remove bolt towards rear.
Installation:
Note insertion direction of bolt.
Fig. 97: Mark Position, Eccentric Screw, Nut And Removal Direction
If necessary, remove exhaust system bracket from rear axle carrier.

2007 BMW 335i
If necessary, remove rear muffler from body.
Release nut (1) and remove eccentric washer (2).
Pull out eccentric screw and remove camber arm (3).
Installation:
Note insertion direction of eccentric screw.
Align eccentric screw by means of marking to camber arm.
Fit eccentric washer (2).
Replace nut (1).
Fig. 98: Eccentric Washer, Camber Arm And Nut

Replacement:
Replace lower spring pad (refer to Removing And Installing/Replacing Coil Spring).
Version with xenon lights:
Release screw (1) and remove bracket (2).
For tightening torque refer to 37 14 4AZ in 37 14 ELECTRIC COMPONENTS .

2007 BMW 335i
Fig. 99: Lower Spring Pad Bracket And Screw

After installation:
33 32 195 REPLACING RUBBER MOUNT FOR CAMBER ARM IN REAR AXLE CARRIER
 33 4 450
 33 4 451
 33 4 452
 33 4 455
 33 4 456
 33 4 461
 33 4 462
 33 4 463
 33 4 464
 33 4 465
 33 4 466
cooled down.
 Remove coil spring

2007 BMW 335i
 Remove camber arm from rear axle carrier
Pull rubber mount together with special tools 33 4 455, 33 4 456, 33 4 452 and 33 4 451.
Draw rubber mount into rear axle carrier so that slot (1), rubber mount center point and notch (2) form a line.
2007 BMW 335i
Fig. 102: Rubber Mount Centre Point And Notch

Draw rubber mount as far as possible into rear axle carrier with special tools 33 4 461, 33 4 463, 33 4 466 and
33 4 465.
Remove special tool 33 4 450 and draw in rubber mount as far as it will go.
After installation:
Release clips (1).

2007 BMW 335i
Remove cover (3).
Installation:
Replace damaged clips.
Make sure underbody cover is correctly seated.
Fig. 104: Underbody Cover, Clips And Screw

51 71... REMOVING AND INSTALLING/REPLACING REAR MIDDLE TENSION STRUT (UP TO

03/2007)
See REMOVING AND INSTALLING/REPLACING REAR MIDDLE TENSION STRUT (UP TO

03/2007) .

03/2007)
See REMOVING AND INSTALLING/REPLACING REAR MIDDLE TENSION STRUT (FROM

03/2007) .
AXLE MOUNTING
33 33 001 REPLACING LEFT OR RIGHT REAR AXLE CARRIER COMPRESSION STRUT
IMPORTANT: Observe safety instructions for raising the vehicle

Driving without compression struts is not permitted!
Risk of damage!
The rear axle carrier must be supported at the front is both compression struts have to be replaced!
2007 BMW 335i
 Remove UNDERBODY COVER
Release screws (1).
Installation:
Replace screws.
Tightening torque: see 2AZ in 33 33 REAR AXLE SUSPENSION .
Release screw (3) and remove compression strut (2).
Installation:
Check threads for damage; if necessary, repair with HELICOIL THREAD INSERTS.
Fig. 105: Identifying Compression Strut With Screws

33 33 101 REPLACING TWO RUBBER MOUNTS (FRONT) FOR REAR AXLE CARRIER
 33 4 140
 33 4 142
 33 4 147
 33 4 149
 33 4 431
2007 BMW 335i
 33 4 432
 33 4 433
 33 4 434
 33 4 435
 33 4 436
 33 4 437
 33 4 441
 Lower rear axle carrier
If necessary, assemble special tools 33 4 140, 33 4 142 and 33 4 147 as illustrated.
If necessary, position new thrust pieces 33 4 149 with countersunk screws on special tool 33 4 140.
Coat top edge of rubber mount with Circo Light.
Fit special tool 33 4 441 on rubber mount in such a way that edge of rubber mount disappears in special tool.
Oil special tool 33 4 436 slightly before use.
Align special tool 33 4 140 by way of openings in rubber mount.
NOTE: Ensure it is correctly supported on bearing bushing of rear axle carrier.
Withdraw rubber mount from bearing bushing with special tools 33 4 436, 33 4 437, 33 4 140 and 33 4 431.
2007 BMW 335i
Installation:
Coat new rubber mount with Circo Light.
Assemble special tools 33 4 432, 33 4 433, 33 4 435 and 33 4 434 as illustrated.
Align rubber mount by way of arrow to direction of travel.
After installation:
2007 BMW 335i
 Bleed brakes
33 33 101 REPLACING TWO RUBBER MOUNTS (REAR) FOR REAR AXLE CARRIER
 33 4 140
 33 4 142
 33 4 147
 33 4 149
 33 4 431
 33 4 434
 33 4 435
 33 4 436
 33 4 437
 33 4 441
 33 4 442
 33 4 443
 33 4 444
If necessary, assemble special tools 33 4 140, 33 4 142 and 33 4 147 as illustrated.
If necessary, screw new thrust pieces 33 4 149 with countersunk screws on special tool 33 4 140.
2007 BMW 335i
Coat top edge of rubber mount with Circo Light.
Fit special tool 33 4 441 on rubber mount in such a way that edge of rubber mount disappears in special tool.
Align special tool 33 4 140 by way of openings in rubber mount.
NOTE: Ensure it is correctly supported on bearing bushing of rear axle carrier.
Withdraw rubber mount from bearing bushing with special tools 33 4 436, 33 4 437, 33 4 140 and 33 4 431.
Installation:
Coat new rubber mount with Circo Light.
Insert special tool 33 4 444 in opening on rear axle carrier to avoid damaging the rear axle carrier when drawing
in the rubber mount.
Assemble special tools 33 4 442, 33 4 443, 33 4 435 and 33 4 434 as illustrated.
Align rubber mount by way of arrow to direction of travel.

2007 BMW 335i
After installation:
 Bleed brakes
WHEEL BEARINGS
3341... DETACHING WHEEL BEARING INNER RACE FROM DRIVE FLANGE (DRIVE FLANGE
REMOVED)
NOTE: Detach wheel bearing ring with special tool 33 4 400 through groove in wheel
bearing inner ring.
Position Synchronizing key special tool 33 1 307 on drive flange.
Select one of the following special tools using the wheel bearing inner ring and insert into special tool 33 4
401 .
33 4 405 for dia. 45 - 51 mm
33 4 406 for dia 50 - 55 mm
33 4 407 for dia. 55 - 61 mm
Screw out special tool 33 4 402 until the tapered attachment of the spindle comes into contact with the special
tool 33 4 401 .
Position special tool 33 4 401 with the corresponding insert on groove of wheel bearing inner ring.
2007 BMW 335i
Fig. 112: Locating Groove Of Wheel Bearing Inner Ring

Compress special tool 33 4 401 with wrenches 33 4 403 and 33 4 404 until the special tool can still be turned in
the groove.
Detach wheel bearing inner ring by turning special tool 33 4 402.
Fig. 113: Removing Wheel Bearing Inner Ring By Turning Special Tool 33 4 402
33 41 005 REPLACING LEFT DRIVE FLANGE ON REAR AXLE SHAFT
 33 2 116
 33 2 160
2007 BMW 335i
 33 2 201
 33 4 200

 Remove brake disk
 Remove pulse generator
Force drive flange with special tools 33 2 116 / 33 2 201, 33 2 160, 33 4 200 and 5 wheel bolts out of wheel
bearing.
NOTE: Rounded inside edge of special tool 33 2 160 must point to drive flange.
IMPORTANT: The wheel bearing is destroyed when the drive flange is removed and cannot
be reused!
Replace wheel bearing.
Installation:
Install output shaft.
Oil drive flange lightly and attach to splines of output shaft.
Draw drive flange into wheel bearing.
After installation:
2007 BMW 335i
33 41 007 REPLACING RIGHT DRIVE FLANGE ON REAR AXLE SHAFT
NOTE: The procedure is described in the document "Replacing drive flange on rear
axle shaft on left".
33 41 153 REPLACING WHEEL BEARING (75 MM) ON REAR AXLE SHAFT ON LEFT
 33 4 031
 33 4 041
 33 4 042
 33 4 043
 33 4 047
 33 4 048
 33 4 049
 Remove drive flange of rear axle shaft
Press retaining ring (1) together using pliers and remove.
Installation:
Install retaining ring (1).
Check seating of retaining ring (1), correct if necessary.

2007 BMW 335i
Pull out wheel bearing with special tools 33 4 041, 33 4 042, 33 4 031, 33 4 048 and 33 4 043.
IMPORTANT: Do not reuse old wheel bearing!
Installation:
Draw in new wheel bearing (1) with special tools 33 4 041, 33 4 042, 33 4 049, 33 4 047 and 33 4 043.
Fig. 117: Wheel Bearing, Special Tools (33 4 041), (33 4 047), (33 4 049), (33 4 043) And (33 4 042)
After installation:
33 41 153 REPLACING WHEEL BEARING (85 MM) ON REAR AXLE SHAFT ON LEFT
2007 BMW 335i
 33 3 261
 33 3 262
 33 3 263
 33 3 264
 33 3 265
 Remove drive flange of rear axle shaft
Press retaining ring (1) together using pliers and remove.
Installation:
Replace circlip.
Check seating of circlip, correct if necessary.

Pull out wheel bearing with special tools 33 3 261, 33 3 263 and 33 3 262.
2007 BMW 335i
IMPORTANT: Do not reuse old wheel bearing!
Black-dyed multipole seal (1) must point to center of vehicle!
Fig. 120: Black-Dyed Multipole Seal

Installation:
Check installation position of wheel bearing (1), correct if necessary.
Draw in wheel bearing (1) with special tools 33 3 261, 33 3 265 and 33 3 264.
2007 BMW 335i
Fig. 121: Wheel Bearing, Special Tools (33 3 261), (33 3 264) And (33 3 265)
After installation:
33 41 155 REPLACING RIGHT WHEEL BEARING ON REAR AXLE SHAFT
NOTE: Procedure is described in the document "Replacing wheel bearing on rear axle
shaft on left".
SHOCK ABSORBER
3300... INFORMATION ON REPLACING SHOCK ABSORBERS
Situation
E32, E34, E38, E39: With the rear spring struts with self-levelling suspension, a slight oil leak usually exists at
the piston rod. These spring struts are permitted to be wet with oil over a maximum of half the shock absorber
length on the outer tube, i.e. they are permitted to "sweat".
Effect
removed shock absorbers as defective parts. Unnecessarily high costs for the customer can be avoided by
Procedure
2007 BMW 335i
If one shock absorber is damaged, it is only necessary to replace both shock absorbers when the car has driven
in excess of 80 000 km.
Information on replacing shock absorbers on E65/E66 models with EDC before production 03/07
Component version (build date) before 03/07:
 Both shock absorbers must be replaced.
Component version (build date) after 03/07:
 The shock absorbers can be replaced again individually.
If in doubt, always replace both shock absorbers.
33 52 000 REMOVING AND INSTALLING/REPLACING REAR LEFT OR RIGHT SHOCK

ABSORBER
Car may tilt off lifting platform if the workshop jack is incorrectly handled.
After supporting components, make sure that:

 Remove rear wheel

 Remove luggage compartment wheel arch trim
NOTE: Read and comply with Information on replacing shock absorbers.
Support wheel carrier with workshop jack.
Release nut; if necessary brace on hex head.
Raise wheel carrier with workshop jack until shock absorber can be removed from rubber mount.
Press shock absorber together and remove from rubber mount.

2007 BMW 335i
Slowly lower wheel carrier until wheel carrier is suspended.
Remove workshop jack underneath car and lower car.
Installation:
For tightening torque refer to 33 52 2AZ in 33 52 SHOCK ABSORBERS .
Fig. 122: Self-Locking Nut

E93: Remove cable duct.
Remove protective cap.
Release nut (1); if necessary, grip at hexagon head.
Remove support bearing upper section (2).
Installation:
Replace support bearing upper section (2).

2007 BMW 335i
Fig. 123: Support Bearing Upper Section And Nut

Press shock absorber together and remove from wheel arch.
Installation:
Remove support bearing (lower section), check for damage and if necessary replace.
Check auxiliary damper and protective tube for damage, replace if necessary.
Fig. 124: Shock Absorber And Wheel Arch

Replacement:
 Remove support pot (1) and auxiliary damper (2) with protective tube (3) from rear shock absorber (4)
2007 BMW 335i
Fig. 125: Support Pot, Auxiliary Damper, Protective Tube And Rear Shock Absorber
33 52 031 REPLACING REAR LEFT OR RIGHT RUBBER MOUNT FOR SHOCK ABSORBER
MOUNTING
Car may tilt off lifting platform if the workshop jack is incorrectly handled.
Release nut; if necessary brace on hex head.
Raise wheel carrier with workshop jack until shock absorber can be removed from rubber mount.
Installation:
Fig. 126: Self-Locking Nut

2007 BMW 335i
Release screws (1).
Press shock absorber upwards and remove rubber mount (2) from camber arm.
Fig. 127: Camber Arm Rubber Mount And Screws

33 52 161 REPLACING THRUST BEARING (LOWER SECTION) FOR REAR LEFT OR RIGHT
SPRING STRUT/SHOCK ABSORBER
 Remove rear shock absorber
Press support bearing lower section (1) with seal grommet (2) out of shock absorber mounting.
Installation:
Clean shock absorber mounting including contact surface (3) all round.
Insert thrust bearing lower section (1) in sealing grommet (2).

2007 BMW 335i
Fig. 128: Thrust Bearing Lower Section, Shock Absorber Mounting Contact Surface And Sealing
Grommet
Installation:
Coat sealing grommet as illustrated with Circolight and press into shock absorber mounting.
Fig. 129: Sealing Grommet Coat Area

SPRINGS WITH SUSPENSION

33 53... MEASURING RIDE-LEVEL HEIGHT OF VEHICLE
2007 BMW 335i
Fig. 130: Actual Ride Height (A), Rim Flange And Wheel Arch
33 53 000 REMOVING AND INSTALLING / REPLACING REAR LEFT OR RIGHT COIL SPRING
 33 5 011
 33 5 012
 33 5 013
 33 5 014
 33 5 015
 33 5 016
 33 5 017
 33 5 020
WARNING: Observe the following instructions to avoid any risk of injury by the coil
springs.
1. Prior to each use, check the special tools for defects, modifications
and operational reliability.
4. These special tools are intended solely for the purpose of tightening
and relieving cylindrical and tapered suspension springs.
6. Impact screwdrivers may not be used!
7. Do not compress coil spring to full extent.
8. Observe manufacturer's instructions.
2007 BMW 335i
IMPORTANT: Both coil springs on the relevant axle must be replaced only in the event of
corrosion breakage!
 Remove rear wheel.
Removal:
Insert lower spring plate 33 5 012 centrally into coil spring and turn to lowest coil.
Guide spindles 33 5 013, 33 5 014, 33 5 015 from below through camber arm and lower spring plate 33 5 012.
Fig. 131: Special Tool (33 5 013), (33 5 014), (33 5 015), (33 5 012) And Installation Directions
Insert upper spring plate 33 5 011 sideways into coil spring and turn to uppermost coil.
IMPORTANT: Make sure spindle (hexagon) is correctly seated in upper spring plate 33 5 011.
Pull spindle 33 5 013 downwards.

2007 BMW 335i

Make sure coil spring is correctly positioned in spring plates.
Fig. 133: Coil Spring Correct Positioned In Spring Plates

IMPORTANT: Align special tools 33 5 011, 33 5 012, 33 5 013, 33 5 014, 33 5 015 centrally to
obtain the biggest possible contact surface on the coil spring.
Check installation position of special tools 33 5 011, 33 5 012 and 33 5 013, 33 5 014, 33 5 015, correct if
necessary.
2007 BMW 335i
Tension coil spring using special tools 33 5 016 and 33 5 020, gripping spindle of spring tensioner with special
tool 33 5 017 in the process.
Remove coil spring upwards.
If necessary, relieve tension on coil spring.
IMPORTANT: Replacement only:
Bottom end of coil spring (1) must be flush with opening of spring plate 33 5
012 (see dotted-dashed line in Fig. 136)!
2007 BMW 335i
Fig. 136: Coil Spring Bottom End And Special Tool (33 5 012)
Installation:
Check spring mounts (2, 3) for damage, replace if necessary.
Remove spring plate (1) and position with upper spring pad (2) on coil spring.
NOTE: Upper spring pad (2) must come into contact with end of coil spring.
Version with rough road package: Install adapter as well.
Fig. 137: Spring Mounts And Spring Plate

IMPORTANT: Observe the following when installing and relieving tension on coil spring:
 Lower spring pad must be positively seated in the designated receptacle

2007 BMW 335i
in the camber arm
NOTE: Otherwise there is a risk of the coil spring jumping out sideways.
 Lower spring pad must come into contact with end of coil spring (see
arrow in Fig. 138)
 Lower spring pad must rest flush on last coil (see broken line in Fig. 138)
Fig. 138: Coil Spring

Align coil spring by way of spring plate to opening in side member and relieve tension.
Remove special tools 33 5 011, 33 5 012 and 33 5 013, 33 5 014, 33 5 015.
After installation:
2007 BMW 335i
 Check headlight adjustment , correct if necessary
STABILIZER BAR
33 55 000 REMOVING AND INSTALLING / REPLACING REAR ANTI-ROLL BAR

 Remove left control arm on wheel carrier
 Remove stabilizer link on both sides from stabilizer
NOTE: To simplify the illustration, removal of the stabilizer is depicted on the removed
rear axle.
Release screws (1).
Remove rubber mount on both sides from stabilizer.
Turn stabilizer (2) and remove sideways.
Installation:
Check rubber mount on both sides for damage, replace if necessary.
For tightening torque refer to 1AZ in 33 55 STABILIZER BAR .
Fig. 140: Stabilizer And Screws

After installation:
2007 BMW 335i
 Bleed brakes
33 55 021 REPLACING BOTH RUBBER MOUNTS FOR ANTI-ROLL BAR MOUNTING
 Remove rear wheels
Release screws (1).
For tightening torque refer to 33 55 1AZ in 33 55 STABILIZER BAR .
Remove retaining bracket (2) and rubber mount (3).
Installation:
Keep retaining bracket (2), rubber mount (3) and stabilizer clean and free from oil and grease.
Clean rear stabilizer on both sides.
Position rubber mount on rear stabilizer.
Position retaining bracket on rubber mount.
Push rubber mount with retaining bracket on rear stabilizer to installation position.
Fig. 141: Screws, Retaining Bracket And Rubber Mount

3355041 REPLACING ANTI-ROLL BAR LINK FOR ANTI-ROLL BAR ON LEFT OR RIGHT
Release nut (1), brace with special tool 31 1 140 OPEN-END WRENCH WAF 16/18 .
2007 BMW 335i
Installation note:
Release screw (3).
Remove stabilizer link (2) towards top.
Fig. 142: Identifying Stabilizer Link With Nut And Screw

TROUBLESHOOTING
33 90... REAR AXLE TROUBLESHOOTING
Observe troubleshooting for shock absorbers.
REAR AXLE TROUBLESHOOTING CHART

Fault Cause Remedy
Grinding noise (only when Refer to Troubleshooting brake system
cornering) Wheel bearings faulty Replace wheel bearings
Vibration (90 - 160 km/h) Wheel imbalance Balance wheels
Radial/lateral rim runout Check rims , replace if necessary
Radial tire runout Match or replace tires
Imbalance in output shaft Replace output shaft
Drumming Rubber mount of final drive Replace rubber mount
suspension faulty
Rubber mount of rear axle carrier Replace rubber mount
2007 BMW 335i
faulty
Rattling noise Refer to TROUBLESHOOTING FOR SHOCK ABSORBERS.
Stabilizer link loose or defective Check screw connection, replace
stabilizer link if necessary
Rubber mount of rear axle carrier Check seat, replace rubber
loose or faulty mount if necessary
Poor straight-running stability Rubber mount of rear axle carrier Replace rubber mount
(steering wheel inclination) faulty
Rubber mount on traction strut Replace traction strut
faulty
Rubber mount of control arm Replace control arms
faulty
Rubber mount for trailing arm in Replace rubber mount
rear axle carrier or wheel carrier
faulty
Rubber mount of toe arm faulty Replace toe arm
Rubber mount/ball joint for Replace rubber mount/ball joint
camber arm faulty
Rear axle alignment incorrectly Carry out chassis/wheel
adjusted alignment check , align rear axle
if necessary
Unsteady taking of curves due to Refer to "Poor straight-running stability"
self-steering or poor rear end track
stability Refer to TROUBLESHOOTING FOR SHOCK ABSORBERS.
Excessive tire wear Rear axle alignment incorrectly Carry out chassis/wheel
adjusted alignment check , align rear axle
if necessary
33 90... TROUBLESHOOTING SHOCK ABSORBER
Read and comply with Information on replacing shock absorbers.
SHOCK ABSORBER TROUBLESHOOTING CHART

Fault Cause Remedy
Wheel knocking (bottoming) Auxiliary spring faulty Visually inspect auxiliary spring
for cracking, replace auxiliary
spring
Rattling noise Shock absorber mounting loose Tighten shock absorber
Support bearing loose Secure support bearing
Support bearing defective Visually inspect for cracking,
(cracked) replace support bearing
Protective tube defective/failed Visually inspect protective tube
for cracking, replace protective
2007 BMW 335i
tube
Rubber mount/joint eye for lower Replace rubber mount/joint eye
shock absorber mounting
defective
Worn down areas (flattened areas) Shock absorber leaking (gas/oil) Replace shock absorber
on tire profile
Long after-swinging of body after Shock absorber leaking Replace shock absorber
driving over rough road (insufficient shock absorber
effect)
Building-up of body in case of Shock absorber leaking Replace shock absorber
successive uneven surfaces (insufficient shock absorber
effect)
Wheels jumping even on normal Shock absorber leaking Replace shock absorber
road surfaces (insufficient shock absorber
effect)
2007 BMW 335i
ACCESSORIES AND EQUIPMENT Seats - Repair Instructions
Seats - Repair Instructions
FRONT SEAT, NORMAL, MANUAL

52 13... REPLACING GUIDE SLEEVES FOR FRONT LEFT OR RIGHT HEAD RESTRAINT
 52 0 070
 Remove Front Head Restraint
NOTE: Guide sleeves cannot be removed without being damaged.
Guide sleeves with push-buttons have two retaining lugs.
Insert special tool 52 0 070 into guide hole of sleeve (2) up to upper area of retaining lug.
Feed release tongue of special tool in to gap on retaining lug (1).
Turn special tool to release sleeve (2) and pull out towards top.
If necessary, on guide sleeves with push-buttons, unlock the second retaining lug with a screwdriver.
Fig. 1: Identifying Sleeve Guide Hole, Lugs And Special Tool (52 0 070)
Installation:
2007 BMW 335i
Replace guide sleeves and install as follows:
1. Guide sleeve with push-button (3) and two retaining lugs, left
2. Guide sleeve without push-button and one retaining lug, right
Fig. 2: Identifying Guide Sleeve Push-button And Retaining Lugs

52 13 000 REMOVING AND INSTALLING LEFT OR RIGHT FRONT SEAT (NORMAL / MANUAL)
 Remove Head Restraint
WARNING: Read and comply with Safety Regulations for handling airbag modules
and pyrotechnical belt tensioners.

tensioner or side airbag, resulting in injuries.
Release screws (1).
Installation:
Replace screws.
For tightening torque refer to 1AZ in 52 10 FRONT SEATS
Move front seat as far back as possible.

2007 BMW 335i
Fig. 3: Identifying Seat Rail Screws

Release screws (3).
Installation:
Replace screws.
For tightening torque refer to 1AZ. in 52 10 FRONT SEATS
Unlock plug connection (1) and disconnect plug (2).
IMPORTANT: Cover door sill with protective covers (risk of damage).
Lift out front seat.
Fig. 4: Identifying Plug Connection, Plug Connection Lock And Screws

Installation:
2007 BMW 335i
Carpet must not get between seat rails and floor pan in area of fastening points (grating noises).
52 13 021 REMOVING AND INSTALLING / REPLACING FLEXMAT ON LEFT OR RIGHT FRONT

SEAT
 Remove padding for front seat
Cut all cable ties and disengage wiring harnesses from flexmat.
Fig. 5: Locating Front Seat Wiring Harnesses

Disengage flexmat (1) at front.
Fig. 6: Identifying Front Seat Flexmat

Swing flexmat (1) down and disengage from seat frame.

2007 BMW 335i
Fig. 7: Swing Flexmat Down And Disengage From Seat Frame

52 13 025 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT SEAT MECHANISM

(NORMAL/MANUAL)
 Remove Seat Cover for front seat

 Remove Backrest Frame on front seat
 Remove Seatbelt Tensioner
 Remove Control Unit For Seat Heating
Disconnect all cable straps.
Unlock plug housing (1) from flexmat and disconnect.
Release seat wiring harness (2) from cable holders on seat mechanism.
Fig. 8: Identifying Plug Housing And Wiring Harness

2007 BMW 335i
52 13 030 REMOVING AND INSTALLING/REPLACING BACKREST FRAME ON LEFT OR RIGHT

FRONT SEAT

 Remove Rear Panel on front seat backrest
Release airbag wiring harness (2) from cable holders on seat mechanism.
Raise release clip (3) and pull plug (4) out of plug housing (1).
NOTE: If necessary, release yellow plug housing (1) from holder on seat mechanism.
Fig. 9: Identifying Plug, Wiring Harness, Clip And Plug Housing

Release wiring harness (3) from cable holders on seat mechanism.
IMPORTANT: Feed all wiring harnesses carefully through the seat and backrest mechanism
as the edges of the frame can be sharp.
2007 BMW 335i
Fig. 10: Identifying Plug Connections And Wiring Harness

E92 only:
Lever out retaining clip (1) on left and right.
Installation:
Replace retaining clip (1).
Make sure retaining clip (1) is correctly seated.
Fig. 11: Identifying Retaining Clip

E92 only:
Unhook seat covers on left and right.
Unclip ball socket (1) from ball head on left and right.
Installation:
2007 BMW 335i
Ball socket (1) must snap audibly into place.
Ball socket (1) must be able to move freely on ball head.
Unclip guide (2) for Bowden cable with plastic wedge.
Fig. 12: Identifying Ball Socket And Guide

Unhook seat covers (1) on left and right.
Release screws (2) on left and right.
Remove backrest frame (3) completely towards top.
Fig. 13: Identifying Backrest Frame, Seat Covers And Screws

Replacement:
2007 BMW 335i
 Remove Backrest Cover with padding.
52 13 034 REMOVING AND INSTALLING/REPLACING RELEASE MECHANISM ON LEFT OR

RIGHT FRONT SEAT (NORMAL/MANUAL)

 Remove Rear Panel
Lever out trim in upward direction (1) with plastic wedge.
Slide trim forwards (2) and feed out over release handle.
Installation:
Check tabs (3) for correct seating in release mechanism.
Clip trim noticeably in to place.
Fig. 14: Identifying Trim Removal Directions And Tabs

Front seat (electric) only:
Replacement only:
Unclip switch (2).

2007 BMW 335i
Fig. 15: Identifying Front Electric Seat Plug Connection And Clip Switch
Detach backrest cover in marked area.
Fig. 16: Locating Backrest Cover

IMPORTANT: Danger of mixing up screws.
Release screws (1).
Release screw between backrest cover and release mechanism.

2007 BMW 335i
Fig. 17: Identifying Backrest Cover And Screws

Feed Bowden cables (1) out of cable holder (2).
Unclip cable holder (3) from backrest frame.
Fig. 18: Identifying Bowden Cables And Cable Holders

Unhook seat covers on left and right.
Lever out retaining clip (1) on left and right.
Installation:
Replace retaining clip (1).
Make sure retaining clip (1) is correctly seated.

2007 BMW 335i
Fig. 19: Identifying Retaining Clip

Unclip ball socket (1) from ball head on left and right.
Installation:
Ball socket (1) must snap audibly into place.
Ball socket (1) must be able to move freely on ball head.
Feed Bowden cable out of guide (2) and backrest frame.
Fig. 20: Identifying Ball Socket And Guide

52 13 040 REMOVING AND INSTALLING/REPLACING OUTER COVER ON LEFT OR RIGHT

FRONT SEAT BACKREST (NORMAL / MANUAL)
 00 9 317
2007 BMW 335i
NOTE: Picture shows installed seat by way of example.
Raise lock (3) and lever out handle
1. for backrest angle adjustment and

2. for seat height adjustment
with special tool 00 9 317 .
Fig. 21: Identifying Seat Lever Lock, Back Rest Adjustment And Seat Height Adjustment Levers
Release screw (1).
'For tightening torque refer to 6AZ in 52 10 FRONT SEATS .
NOTE: Trim (2) is engaged in marked area.

Press lock (3) and pull trim (2) off seat mechanism.
If necessary, lever out carefully with special tool 00 9 317 .

2007 BMW 335i
Fig. 22: Identifying Seat Trim, Lock And Retaining Bolt

Model with lumbar supports:
Fig. 23: Identifying Lumbar Support Plug Connection

Replacement only:
Unlock catches (1) on left and right and remove switch (2) from trim (3).
2007 BMW 335i
Fig. 24: Identifying Seat Catches, Switch And Trim

52 13 041 REMOVING AND INSTALLING / REPLACING INNER COVER ON LEFT OR RIGHT

FRONT SEAT BACKREST (NORMAL/ MANUAL)
Release screw (1).
Lever clip (2) out of seat cover on left and right.
Installation:
If necessary, replace faulty clip.
Remove trim (3) from inside of seat.
Fig. 25: Identifying Front Seat Trim, Clip And Screw

2007 BMW 335i
52 13 198 REMOVING AND INSTALLING/REPLACING REAR PANEL ON LEFT OR RIGHT

FRONT SEAT BACKREST
Release clips (1) with diagonal cutting pliers.
Remove rear panel (2) downwards with a turning action.
NOTE: Remove remnants of clips.
Fig. 26: Identifying Front Seat Rear Panel And Clip

Installation:
Retaining hooks (1) and bore holes (2) on rear panel (3) must not be damaged.

2007 BMW 335i
Fig. 27: Identifying Front Seat Rear Panel, Retaining Hooks And Bore Holes
52 13 390 REMOVING AND INSTALLING OR REPLACING FRONT LEFT OR RIGHT HEAD

RESTRAINT
Press catch (1) and lift out head restraint (2).
Fig. 28: Identifying Catch And Head Restraint

52 13 400 REPLACING SEAT COVER ON LEFT OR RIGHT FRONT SEAT (NORMAL/MANUAL)
 52 0 050

 Remove Rear Panel on front seat backrest
WARNING: US/CDN front passenger seat (with OC3 mat) only:
To avoid damaging the OC3 mat, it is essential to carry out the following
operations with extra care.
When replacing seat cover:
If seat cover is defective, seat cover and padding with OC3 mat must be replaced together.
New seat cover is supplied with padding, OC3 mat and if necessary seat heating.
2007 BMW 335i
When replacing padding with OC3 mat:
If OC3 mat or padding is defective, both parts may only be replaced together.
These must be fitted with the seat cover from the car.
After fitting seat cover, enable OC3 mat with BMW diagnosis system.
Enabling seat occupancy detector (OC3 mat):
 Connect BMW diagnosis system

Version with seat heating only:
IMPORTANT: Feed the wiring harness carefully through the seat and backrest mechanism as
the edges of the frame can be sharp.
Fig. 29: Identifying Plug Connection And Wiring Harness

Release screw (1).
Installation:
2007 BMW 335i
Fig. 30: Identifying Front Seat Trim, Clip And Screw

Detach seat cover (1) from seat frame.
Fig. 31: Detaching Seat Cover From Seat Frame

Pull out cover welt (1) completely from seat frame (2).
2007 BMW 335i
Fig. 32: Identifying Cover Welt And Seat Frame

Remove seat cover (1) with support towards front/top.
Fig. 33: Identifying Seat Cover

Version with seat heater and/or with seat occupancy detector (OC3 mat):
Pull seat cover (1) with support forward a little and feed cable (2) out.
Remove seat cover (1) with support towards front/top.

2007 BMW 335i
Fig. 34: Identifying Seat Cover And Cable

Replacing seat cover:
Version with OC3 mat:
 OC3 mat must not be kinked under any circumstances.
Carefully detach all retainers in side area from longitudinal wires (1).
Pull trim wires (1) forward out of seat cover.
Carefully fold back seat cover and release retainers from cross-wires (2).
Remove seat cover from padding.
Fig. 35: Identifying Trim Wires And Cross Wires

2007 BMW 335i
IMPORTANT: Remove all remnants of clips from seat cover and padding.
Padding (1) with OC3 mat (2).
IMPORTANT: No retainer remainders may be fitted as well.
Handle OC3 mat with extreme care.
Do not kink OC3 mat.
Do not clamp OC3 mat.
OC3 mat must lie without folds under seat cover.
Fig. 36: Identifying Front Seat Padding And OC3 Mat

Replacement only:
If necessary, cut new seat cover to size and insert trim threads.
2007 BMW 335i
Fig. 37: Identifying Trim Threads

Installation:
Bend new clips (2) with special tool 52 0 050
1. Padding
2. Retainer
3. Trim thread in padding
4. Trim thread in cover
5. Seat cover
Fig. 38: Identifying Front Seat Cover, Padding, Retainer, Trim Threads, Clips, And Special Tool
(52 0 050)
52 13 405 REPLACING BACKREST COVER FOR LEFT OR RIGHT FRONT SEAT (NORMAL /
MANUAL)
 52 0 050

 Remove Guide Sleeves
 Remove Cover For Release Mechanism

2007 BMW 335i

Detach backrest cover (1) from backrest frame.
Fig. 40: Detaching Backrest Cover From Backrest Frame


2007 BMW 335i
Fig. 41: Locating Backrest Cover In Marked Area

Detach mounting strip (4) from flexmat.
Carefully pull airbag module (3) with threaded pins out of backrest frame and feed out between padding (1) and
inner bag (2).
Set down airbag module (3) to one side.
Fig. 42: Identifying Inner Bag, Padding, Airbag Module And Mounting Strip
Installation:
Pull inner bag (1) fully over airbag module and threaded pins.
Feed in mounting strip (2) of inner bag (1) through backrest frame.
Insert threaded pins in to backrest frame and secure with new nuts.
2007 BMW 335i
No inner bag material is permitted to project through the hole in the inner frame.
Install nuts and tighten down.
For tightening torques refer to 2AZ. in 72 12 AIRBAG MODULES .
Fig. 43: Identifying Mounting Strip, Inner Bag And Backrest Frame
Installation:
Inner bag must be between airbag module and backrest frame!
Engage mounting strip (1) of inner bag in flexmat.
Position inner bag (2) smoothly over backrest frame.
Engage backrest cover (3) in backrest frame.
Fig. 44: Identifying Mounting Strip, Inner Bag And Backrest Cover
2007 BMW 335i
Pull off backrest cover (1) with padding sideways and towards top from backrest frame.
Fig. 45: Identifying Backrest Cover And Backrest Frame

Release all retainers in marked area.
Remove backrest cover from padding.
NOTE: Remove all remnants of retainers from backrest cover and padding.
Fig. 46: Identifying Remnants Of Retainers

Installation:
Bend new retainer (2) with special tool 52 0 050

2007 BMW 335i
1. Padding
2. Retainer
4. Trim wire in backrest cover
5. Back-rest cover
Fig. 47: Identifying Padding, Trims, Backrest Cover, Retainer And Special Tool (52 0 050)
Replacement of backrest cover:
Pull trim threads out of backrest cover.
Cut new backrest cover to size and insert trim threads.

52 13 415 REPLACING LEFT OR RIGHT SUPPORT FOR FRONT SEAT (NORMAL / MANUAL)
2007 BMW 335i
The support can only be removed in conjunction with the OC3 mat.
If support is defective, both parts may only be replaced together.
After fitting new support, enable OC3 mat with BMW diagnosis system.
The operation for removing the support with/without OC3 mat is described in :
 Replacing Seat Cover On Left Or Right Front Seat.
 Connect BMW diagnosis system

52 13 420 REPLACING LEFT OR RIGHT SUPPORT FOR FRONT SEAT BACKREST (NORMAL /
MANUAL)
This operation is described in section on:
Replacing Backrest Cover For Left Or Right Front Seat.
52 13 455 REPLACING HEATING ELEMENTS FOR LEFT OR RIGHT FRONT SEAT (BASIC)
 Remove Seat Cover
NOTE: Heating element is bonded to the foam section and cannot be separated from
each other without incurring damaging.
Foam section and heating mat must be replaced.
Check new foam section:
 No obvious damage or material defects

 All trim wires present in foam
 No bubbles in foam section
 No dirt/contamination on foam or residual foam
 Pay attention to foam section on left and right
Check new heating mat:

2007 BMW 335i

 All tear-off film pieces presents
 Note variant by examining label on cable
Guide cable for backrest heating through foam hole.
Stick on main section (1):
 Pull adhesive film pieces off main section (1) and stick to upper edge of main section foam until flush
Stick on bead section (2):
 Pull adhesive film pieces off bead section (2) and stick on heating mat along bead section edges.
 Press down evenly in outwards direction
Fig. 49: Identifying Main Section And Bead Section

Guide cable for seat heating through foam hole.
2007 BMW 335i

Check laying of heating mats:
 Heating mats laid without folds

 Heating mats correctly positioned
 All bonding surfaces stuck on
NOTE: Carry out Function Check.
65 77 604 REPLACING SENSOR MAT (OC3 MAT) FOR PASSENGER SEAT OCCUPANCY
DETECTOR
WARNING: Note SAFETY REGULATIONS !


The OC3 mat can only be removed in conjunction with the padding from
the seat cover.
If OC3 mat or padding is defective, both parts may only be replaced
together.
After fitting seat cover, enable OC3 mat with BMW diagnosis system.
Operation for replacing the OC3 mat in conjunction with padding and seat cover is described in:
 Remove PADDING FOR FRONT SEAT.
 Connect BMW PROGRAMMING SYSTEM

 Code airbag control unit
2007 BMW 335i
FRONT SEAT, NORMAL, ELECTRIC

52 14... ADDITIONAL WORK IN EVENT OF FAULTY DRIVE/GEARING FOR LONGITUDINAL
ADJUSTMENT
Release screws (1) of rockers for seat height adjustment.
Installation note:
Carefully bend side section back and feed rocker out of top rail.
Tilt front seat back.
Fig. 51: Identifying Rocker Screws


Unclip central connector (2) from seat mechanism.

2007 BMW 335i
Unclip control units (1).
Fig. 53: Identifying Control Units And Seat Mechanism Connector

Release plug connections (1) and disconnect.
Press out pins of expanding rivets (2) and lever out expanding rivets.
Pull drive with short flex shaft out of gearing.
Fig. 54: Identifying Connectors And Expanding Rivets

Slide seat rearward.
Release screws (1) at front.

2007 BMW 335i
Fig. 55: Identifying Seat Screws

Slide seat forward.
Release screws (1) at rear.
Install new drive for longitudinal seat adjustment.
Fig. 56: Identifying Seat Screws

Installation note:
Slide seat rail with opening forwards or back until bushing for flex shaft mounting of worm gear is flush.
2007 BMW 335i
Insert flex shaft.
Fig. 57: Sliding Seat Rail

Installation note:
Slide short flex shaft (1) into forward/back seat adjustment gearing square.
Bend long flex shaft (2) upwards and slide into forward/back seat adjustment gearing.
Installation note:
2007 BMW 335i
PTFE hoses (1) are shrink-fitted onto end pieces.

Installation note:
 Make sure flex shaft is correctly fitted on drive

 Carpet must not get between seat rails and floor panel in area of attachment points (groaning noises)
 Powerlok screws must be replaced and must not be reused
 Powerlok screws are mechanical screw locks with trilobular threads
 Insert all screws loose to avoid twisting
 Tighten down all screws to specified torque
Tightening torque 52 10 1AZ
52 14... PERFORMING FUNCTION CHECK WITH ADAPTER CABLE (FOR SEAT REPAIRS)
 61 4 360
NOTE: The function check on a repaired driver's or front passenger seat can be
performed outside the vehicle by using adapter cable 61 4 360
2007 BMW 335i
Fig. 60: Identifying Adapter Cable

Use:
Adapter cable 61 4 360 is connected to vehicle wiring harness (1) and removed seat (2).
Fig. 61: Identifying Seat, Wiring Harness And Adapter Cable (61 4 360)
52 14... REMOVING AND INSTALLING CARRIER FOR OUTER COVER ON LEFT OR RIGHT
FRONT SEAT (ELECTRIC) (COUPE)
 Remove Outer Cover
Detach cable strap (1).
Unlock and disconnect plug connections (2) on servodrive.

2007 BMW 335i
Unscrew bolt (3).
Unclip carrier in marked area and remove.
Installation:
Replace cable strap.
Make sure carrier is correctly seated on seat mechanism.
Fig. 62: Identifying Plug Connections, Cable Strap And Bolt

52 14... REMOVING AND INSTALLING CARRIER FOR OUTER COVER ON LEFT OR RIGHT
FRONT SEAT (ELECTRIC) (CONVERTIBLE)
Release screws (1).
Remove carrier section and carefully feed out wiring harness to prevent retaining tabs from being damaged.
Installation:
Make sure the wiring harness is routed correctly.

2007 BMW 335i
Fig. 63: Identifying Carrier Screws Of Outer Cover

52 14... REMOVING AND INSTALLING OR REPLACING TRIM COVER FOR OUTER FITTING
ON FRONT SEAT (CONVERTIBLE)
 Remove carrier for front cover
Release screw.
Installation:
Fit tab (1) on cover (2).
Fig. 64: Identifying Tab On Cover

1. Remove cover from guide and turn towards bottom rear.

2007 BMW 335i
2. Unclip cover upwards and remove.

52 14... REMOVING AND INSTALLING OR REPLACING TRIM COVER FOR SASH GUIDE ON
LEFT OR RIGHT (CONVERTIBLE)
Lift out cover cap (1) from below with plastic wedge.
Fig. 66: Identifying Cover Cap

Release screw (1).
Installation:
Replace screw (1).
Remove finisher.
2007 BMW 335i
Fig. 67: Identifying Finisher Screw

Remove belt guide - build date (version) from 09/08:
NOTE: Protect belt guide against damage (scratches).

Trims of belt guide at front and rear (1) are destroyed when removed!
Installation:
Pay particular attention to cutting line between both trims.
If the trims are not fully clipped into place, this will result in grinding noises when the belt is pulled.
Fig. 68: Identifying Trims Of Belt Guide At Rear

Release screw on belt guide.

2007 BMW 335i
Fig. 69: Locating Screw On Belt Guide

Release further screw on belt guide and detach belt guide.
Remove complete seat belt with belt guide, inertia reel with flex shaft and coupling gear.
Do not kink flex shaft and do not transport inertia reel by flex shaft.
Fig. 70: Locating Screw On Belt Guide

52 14... REMOVING AND INSTALLING OR REPLACING TRIM COVER (HEADREST TRIM) ON

LEFT OR RIGHT FRONT SEAT (CONVERTIBLE)
 Remove trim for release handle

 Remove head restraint. See head restraint (up to 09/08) or crash-active headrest (from 09/08).
2007 BMW 335i
Release screws (1).
Remove trim cover by pulling upwards.
Fig. 71: Identifying Trim Cover Screws

Remove slide (1) for headrest guide cover.
Pull off foam (2) upwards and to side.
Fig. 72: Identifying Slide And Foam

Release screws (1).
Remove trim cover (2) for seat belt guide.
Installation:
2007 BMW 335i
Insert mandrel straight.
Fig. 73: Identifying Trim Cover Screws

Remove trim cover (1).

52 14... REMOVING AND INSTALLING OR REPLACING TRIM FOR RELEASE HANDLE ON

FRONT LEFT OR RIGHT SEAT (CONVERTIBLE)
 Remove rear panel

 Disconnect BATTERY NEGATIVE LEAD .
IMPORTANT: Screw (1) must not fall between airbag module and backrest frame.
2007 BMW 335i
If necessary, remove AIRBAG MODULE .

No sharp-edged objects permitted in area of side airbag.
Release screw (1).
Unclip side trim cover from backrest.
Installation:
Place seat belt between seat belt guide and trim cover.
Make sure the trim cover is fitted correctly in the guide.
Fig. 75: Identifying Side Trim Cover Screw

Replacement only:
Unclip toggle switch.

2007 BMW 335i
Fig. 76: Locating Plug Connection

52 14... REPLACING SEATBACK RELEASE (LVK MODULE) FOR LEFT OR RIGHT FRONT SEAT
(CONVERTIBLE)
 Remove TRIM COVER
Detach backrest cover from metal retainer.
Lever out welt in marked area.
Fig. 77: Identifying Backrest Cover

Disengaging Bowden cable from seatback release:
Lever out cable counter-support (2).

2007 BMW 335i
Unhook Bowden cable nipple (1).
Fig. 78: Identifying Cable Counter-Support And Bowden Cable Nipple

Mark position of seatback release.
Fig. 79: Marking Position Of Seatback Release

Release screws (1).

2007 BMW 335i

Unclip wiring harness (2).
Remove backrest release (1) from backrest frame downwards in direction of arrow.
Fig. 81: Identifying Wiring Harness And Backrest Release

52 14 000 REMOVING AND INSTALLING LEFT OR RIGHT FRONT SEAT (NORMAL/ELECTRIC)
IMPORTANT: An airbag module and a pyrotechnical seat belt tensioner are installed in the
front seat.
Installation:
 Powerlok screws must be replaced and must not be reused

2007 BMW 335i
 Powerlok screws are mechanical screw locks with trilobular threads
Move seat to upper back position.
Remove seat runner trims.
Release and dispose of screws (3).
Fig. 82: Identifying Screws At Front

Move front seat forwards and position flush with seat runners.
Release and dispose of screws (1).
Fig. 83: Identifying Seat Runners Screws


2007 BMW 335i

Installation:
 Carpet must not get between seat rails and floor pan in area of fastening points (grating noises)
 Replace microencapsulated screws
 Insert all screws loose to avoid twisting
 Tighten down all screws to specified torque
Tightening torque: see 1AZ in 52 10 FRONT SEATS .
WARNING: When carrying out further work on the front seat, it is absolutely
imperative to observe the safety regulations on handling airbag modules
and pyrotechnical seat belt tensioners
52 14 028 REPLACING BACKREST RELEASE CABLE FOR FRONT LEFT OR RIGHT SEAT
(CONVERTIBLE)

 Remove TRIM COVER FOR OUTER FITTING
 Remove INNER COVER
 Remove SEAT BELT PRETENSIONER.
 Disconnect AIRBAG MODULE PLUG CONNECTION.
 Remove COUPLING GEAR.
2007 BMW 335i
Detach Bowden cable from LVK module:
Lever out cable counter-support (2).
Unhook Bowden cable nipple (1).
Fig. 85: Identifying Cable Counter-Support And Bowden Cable Nipple

Unclip bracket for Bowden cable from backrest frame.
Fig. 86: Locating Bowden Cable

Remove toothed segment cover (1) as follows:
 Raise cover in upward direction

 Slide cover upwards and detach
2007 BMW 335i
Fig. 87: Identifying Segment Cover

NOTE: Before removing the backrest, it is essential to move the backrest forwards:
Pull Bowden cable (1) and press backrest forwards.
Fig. 88: Identifying Bowden Cable

Tunnel side:
Release screw (1).
Installation note:
Screw (1) must be replaced.
Tightening torque: 24 +4 Nm.

2007 BMW 335i
Fig. 89: Identifying Backrest Screw

Door side:
Release nut on opposite side from stud (1).
Drive out stud (1) with plastic mallet.
Installation note:
Stud (1) and nut must be replaced.
Fig. 90: Identifying Door Side Stud

Remove backrest frame from seat mechanism as follows:

2007 BMW 335i
Lever tunnel-side backrest frame with screwdriver over bushing.
Then remove backrest frame in upward direction by pulling with alternate movements.
Tunnel-side plastic bushing (1) must not be damaged.
Fig. 91: Identifying Tunnel-Side Plastic Bushing

Disengage return spring (1).
Installation note:
Replace return spring (1).
NOTE: Cover working area.
Do not allow any chips to get into the seat and backrest mechanisms.
Mark rivet (2) with center punch and drill out.

2007 BMW 335i
Fig. 92: Identifying Return Spring And Rivet

Lever out cover (1) with screwdriver.
Fig. 93: Levering Out Cover With Screwdriver

Installation note:
Before fitting kinematic assembly, apply a thin coating of grease to contact surface.
2007 BMW 335i
Fig. 94: Applying Thin Coating Of Grease To Contact Surface

Installation note:
Engage return spring (1) before screwing kinematic assembly into place.
Fig. 95: Engaging Return Spring Before Screwing Kinematic Assembly Into Place
Installation note:
Rivet is replaced by a stud.
Nut must be screwed-on on inside of backrest.
Lug (3) of kinematic assembly must be positioned next to stop (2).
Screw on kinematic assembly.

2007 BMW 335i
Check kinematic assembly for ease of movement.
Fig. 96: Identifying Kinematic Assembly Screw, Lug And Stop

Installation note:
Press cover (1) with positioning pin onto backrest frame.
Fig. 97: Pressing Cover With Positioning Pin Onto Backrest Frame
Overview of finish-assembled (new) Bowden cable from spare part kit .

2007 BMW 335i
Fig. 98: Identifying Bowden Cable

Backrest mounting on door side:
1. Install door-side backrest link (1).

2. Backrest link (1) must be joined centrally on blocking cam (2).
3. Connect stud and tighten nut hand-tight.
Fig. 99: Identifying Door-Side Backrest Link And Blocking Cam

Backrest mounting on tunnel side:
1. Install tunnel-side backrest strut.
IMPORTANT: Plastic bushing must not be damaged
2. Tighten screw hand-tight.

2007 BMW 335i
NOTE: Tighten down stud and screw only after mounting backrest on both sides.
Tightening torque:
 Stud on door side: 40 +5 Nm.

 Screw on tunnel side: 24 +4 Nm.
Fig. 100: Identifying Plastic Bushing

Installation note:
Install toothed segment cover (1).
Make sure Bowden cable is in correct position along spacer
Assemble LVK module and front seat.
Fig. 101: Identifying Toothed Segment Cover

2007 BMW 335i
72 11 041 Removing and installing or replacing front left or right lower belt fitting (seat belt pretensioner)
 Remove FRONT SEAT.
modules and pyrotechnical belt pretensioners. Improper handling can
lead to triggering of the pyrotechnical seat belt pretensioner or side
airbag, resulting in injuries. Switch off ignition!
Installation:

IMPORTANT: Ensure exact cable routing of airbag wiring harness and belt tensioner.
Release connector housing (1) from bracket on seat mechanism.
Unclip cable (3) from seat mechanism.
Unlock plug connection and pull all plugs out of plug housing (1).
Removing wiring harness.
Fig. 102: Identifying Connector Housing, Cable, And Cable Tie

2007 BMW 335i
Installation:
Always feed in cable tie (1) at narrow end of plug housing in direction of arrow.
Cables must be secured with insulation under cable tie.
Firmly tighten cable tie (1) to relieve strain.
It must not be possible to move the cable.
Make sure plug (2) is correctly locked in plug housing (3).
Fig. 103: Identifying Plug Housing, Plug, And Cable Tie

Release screw (1).
Remove belt pretensioner (3).
Installation:
Replace screw (1).
Seat belt pretensioner (3) is coded to prevent incorrect installation (2).

2007 BMW 335i
Fig. 104: Removing Belt Pretensioner

52 14 030 REMOVING AND INSTALLING/REPLACING BACKREST FRAME ON LEFT OR RIGHT

FRONT SEAT (CONVERTIBLE)
 Remove backrest cover

 Remove backrest release
 Remove microswitch .
 Remove coupling gear.
NOTE: Before removing the backrest, it is essential to move the backrest forwards:
Tunnel side:
Release screw (1).
Installation:
Screw (1) must be replaced.

2007 BMW 335i
Fig. 105: Identifying Backrest Screw

Door side:
Release nut on opposite side from stud (1).
Drive out stud (1) with plastic mallet.
Installation:
Stud (1) and nut must be replaced.
Fig. 106: Identifying Door Side Stud

Remove backrest frame from seat mechanism as follows:

2007 BMW 335i
Lever tunnel-side backrest frame with screwdriver over bushing.
Then remove backrest frame in upward direction by pulling with alternate movements.
Tunnel-side plastic bushing (1) must not be damaged.
Fig. 107: Identifying Tunnel-Side Plastic Bushing

Backrest mounting on door side:
1. Install door-side backrest link (1).

2. Backrest link (1) must be joined centrally on blocking cam (2).
3. Connect stud and tighten nut hand-tight.
Fig. 108: Identifying Door-Side Backrest Link And Blocking Cam

Backrest mounting on tunnel side:

2007 BMW 335i
1. Install tunnel-side backrest strut.
IMPORTANT: Plastic bushing must not be damaged
2. Tighten screw hand-tight.
NOTE: Tighten down stud and screw only after mounting backrest on both sides.
Fig. 109: Identifying Plastic Bushing

Tightening torque:
 Stud on door side: 40 +5 Nm.

 Screw on tunnel side: 24 +4 Nm.
Replacement only:
Remove inertia reel unit .
Remove lumbar cushion and valve housing/drive unit and air cushion for backrest width adjustment on
front seat.
72 11 030 Removing and installing or replacing front seat belt (Convertible)
IMPORTANT: Read and comply with safety regulations for handling airbag modules and
pyrotechnical belt pretensioners. Inexpert handling can trigger off the airbag or
the belt pretensioner and thereby cause injuries. If a seat belt which is
damaged due to an accident is exchanged, always check the affected seat for
damage.
2007 BMW 335i
 Remove front seat.

 Remove and install rear panel on front seat.
 Remove trim cover for outer fitting.
 Remove inner cover on front seat.
 Partially detach seat cover.
 Partially detach backrest cover.
IMPORTANT: Do not detach coupling gear from flex shaft. If a new belt system is fitted,
always use a new coupling gear. If a new coupling gear is fitted, always replace
the top belt.
Removing inertia reel with flex shaft and coupling gear: Release screw. Installation: Replace microencapsulated
screw. Tightening torque: 44 Nm. Remove end fitting.

Installation: Plastic washer on end fitting must be fitted! End fitting is coded to prevent incorrect installation.
2007 BMW 335i
Fig. 111: End Fitting Is Coded To Prevent Incorrect Installation

Unclip all cables from guides. Release screw (1). Tightening torque: 2.5 Nm. Release stud (2). Tightening
torque: 3 Nm.
Fig. 112: Release Screw (1) And Stud (2)

Note: Replace driver (1) after removal with a new component as damage cannot be excluded. When removing
driver (1), ensure guide (3) and lever (2) of coupling gear are not damaged. Remove driver (1) from backrest
shaft.
2007 BMW 335i
Fig. 113: When Removing Driver (1), Ensure Guide (3) And Lever (2) Of Coupling Gear Are Not
Damaged
Installation: Do not fit new driver (1) on backrest shaft yet. Backrest must be in as vertical a position as
possible. Driver (1) and lug are positioned at an angle towards top in direction of travel (arrow).
Fig. 114: Driver (1) And Lug Are Positioned At An Angle Towards Top In Direction Of Travel (Arrow)
Installation: Feed driver (1) into slot (3) in lever (2) of coupling gear. Align lever (2) on coupling gear so that
slot (3) is correctly positioned with respect to driver (1).
2007 BMW 335i
Fig. 115: Align Lever (2) On Coupling Gear So That Slot (3) Is Correctly Positioned With Respect To
Driver (1)
Installation: Pin on coupling gear must reach into hole in seat.
Fig. 116: Pin On Coupling Gear Must Reach Into Hole In Seat
Installation: Make sure groove and pin are correctly positioned. Clip flexible shaft (1) into place with coupling
gear (2). Ensure complete engagement by pulling gently on flex shaft. Flexible shaft must not clip out here!
2007 BMW 335i
Fig. 117: Clip Flexible Shaft (1) Into Place With Coupling Gear (2)
Unclip flexible shaft (3) from cable tie (2). Unclip cable tie (1) from backrest.
Fig. 118: Unclip Cable Tie (1) From Backrest

Release nut and remove inertia reel with flexible shaft and coupling gear. Replace nut. Tightening torque: 36
Nm. Installation: Inertia reel is coded to prevent incorrect installation.
2007 BMW 335i
Fig. 119: Inertia Reel Is Coded To Prevent Incorrect Installation

Remove belt guide - build date (version) up to 09/08: Unclip cover (1) with plastic wedge.
Fig. 120: Unclip Cover (1) With Plastic Wedge

Release screw (1). Tightening torque: see 3AZ in 72 11 SEAT BELTS . Remove seat belt guide.
2007 BMW 335i
Fig. 121: Release Screw (1) And Remove Seat Belt Guide
Remove belt guide - build date (version) from 09/08:
NOTE: Protect belt guide against damage (scratches). Trims of belt guide at front and
rear (1) are destroyed when removed!
Fig. 122: Trims Of Belt Guide At Front And Rear (1) Are Destroyed When Removed
Installation: Pay particular attention to cutting line between both trims. If the trims are not fully clipped into
place, this will result in grinding noises when the belt is pulled.
Release screw on belt guide. Tightening torque: see 3AZ in 72 11 SEAT BELTS .
2007 BMW 335i
Fig. 123: Release Screw On Belt Guide

Release further screw on belt guide and detach belt guide. Remove complete seat belt with belt guide, inertia
reel with flex shaft and coupling gear. Do not kink flex shaft and do not transport inertia reel by flex shaft.
Fig. 124: Remove Complete Seat Belt With Belt Guide, Inertia Reel With Flex Shaft And Coupling Gear
52 14 040 REMOVING AND INSTALLING/REPLACING OUTER COVER ON FRONT LEFT OR

RIGHT SEAT (NORMAL/ELECTRIC) (COUPE)
 Move front seat completely upwards and forwards in to end position
Move backrest to full rearward position.
Unclip release tab (2) for belt anchor fitting trim (1) with plastic wedge.
2007 BMW 335i
Fig. 125: Identifying Tab And Belt Anchor Fitting Trim

Unscrew bolt (3).
Lever lugs (1) out of holders (3).
Fig. 126: Identifying Bolt, Lugs And Holders

Raise lug (1) and unlock.
Reach between seat padding and cover (2) and pull cover off carrier section.
2007 BMW 335i
Fig. 127: Identifying Lug And Cover

IMPORTANT: Cover (1) could detach itself in from area with carrier section (2) from seat
mechanism.
Carefully pull cover (1) with carrier section (2) in front area off seat mechanism.
Press unlocking lug (3) with screwdriver and detach cover from carrier section.
Fig. 128: Identifying Lug, Carrier Section And Cover

Unlock and disconnect plug connections:
1. Switch combination
2. Lumbar support
3. Backrest width adjustment
2007 BMW 335i
Fig. 129: Identifying Switch Combination, Lumbar Support And Backrest Width Adjustment
Connections
Installation:
Retaining clips and lugs of cover must not be damaged.
Fig. 130: Identifying Retaining Clips And Lugs

Replacement only:
Unlock catches of switch housing and remove switch from cover.

2007 BMW 335i
Fig. 131: Identifying Lock Catches Of Switch Housing

52 14 040 REMOVING AND INSTALLING/REPLACING OUTER COVER ON FRONT LEFT OR

RIGHT SEAT (NORMAL/ELECTRIC) (CONVERTIBLE)
Move seat upwards.
Lift out bottom tabs (2) and detach cover from carrier.
Unclip cover (1) at top.
Unfasten plug connection and disconnect.
Fig. 132: Identifying Cover And Bottom Tabs

Replacement only:
Raise tabs slightly and remove switch cluster (1).

2007 BMW 335i
Installation:
Tabs and retainers must not be damaged.
Fig. 133: Identifying Switch Cluster

52 14 041 REMOVING AND INSTALLING OR REPLACING INNER COVER ON LEFT OR RIGHT

FRONT SEAT (CONVERTIBLE)
 Remove front seat
NOTE: Press seat belt pretensioner to the side.
Release screws.
Remove cover.
Installation:
Fit tab (1) of seat cover on cover (2).

2007 BMW 335i
Fig. 134: Identifying Tab And Cover

52 14 050 REMOVING AND INSTALLING/REPLACING LUMBAR CUSHION ON FRONT SEAT
 Remove Rear Panel On Front Seat

Unlock quick connector and detach air hoses - blue (1) and red (2) - from valve housing (3).
NOTE: Connections are coded against incorrect assembly.
If necessary, remove Valve Housing.

2007 BMW 335i
Fig. 136: Identifying Valve Housing, Blue And Red Air Hoses
Detach lumbar support (1) from spring wire (2).
Installation:
Attach lumbar support (1) to second and fourth wires from below.
Unclip air hoses (3) from holder.
Fig. 137: Identifying Lumbar Support From Spring Wire

Press back support (1) a little.
Pull out lumbar cushion (2) towards top.
Feed air hoses out of backrest frame and spring wire.

2007 BMW 335i
Fig. 138: Identifying Back Support And Lumbar Cushion

Installation:
Check lumbar support at top (1) and bottom (2) for damage.
Air hoses (3) must not be kinked.
Fig. 139: Identifying Air Hoses, Top And Bottom Lumbar Support
Installation:
Carry out Function Check.
52 14 060 REMOVING AND INSTALLING/REPLACING VALVE HOUSING FOR LUMBAR

CUSHION

2007 BMW 335i

Remove valve housing (2) for lumbar support in direction of arrow from backrest frame.
Installation:
Check valve housing for correct seating in backrest frame.
Fig. 141: Removing Valve Housing From Backrest Frame

Unlock quick connector and detach air hoses (3) and (4 and 5) from valve housing (2).
Valve unit for lumbar support:
(3) Hose (clear), lumbar drive

(4) Hose (blue), top lumbar cushion
2007 BMW 335i
(5) Hose (red), bottom lumbar cushion
Fig. 142: Identifying Valve Housing, Plug Connection, Blue, Red, And Clear Air Hoses
52 14 198 REMOVING AND INSTALLING OR REPLACING REAR PANEL ON LEFT OR RIGHT

FRONT SEAT BACKREST (CONVERTIBLE)
Release screws (1).
Fig. 143: Identifying Front Seat Backrest Screws

1. Carefully pull back rear panel.

2. Remove rear panel by pulling downward.
2007 BMW 335i
Installation:
Insert rear panel at top and slide upwards.
Force in guide on tunnel side.
Force in guide on airbag side.
Pull at side to check guide in backrest frame for correct seating.
Fig. 144: Identifying Rear Panel


RESTRAINT (UP TO 09/08) (COUPE)
Press catch (1) and lift out head restraint (2).
Fig. 145: Identifying Catch And Head Restraint

2007 BMW 335i

RESTRAINT (UP TO 09/08) (CONVERTIBLE)
 Remove belt guide
Remove headrest.
Fig. 146: Identifying Headrest

52 14 392 REMOVING AND INSTALLING/REPLACING FRONT LEFT OR RIGHT CRASH-

ACTIVE HEADREST (FROM 09/08) (COUPE)
WARNING: Observe SAFETY REGULATIONS when handling airbag modules.

Incorrect handling may result in activation of the crash-active head
restraint and thereby cause injury.
Switch off the ignition!

 Remove REAR PANEL
Starting situation:
Head restraint is in the crash position after being triggered.
A triggered head restraint can be recognized by the padded section which has moved upwards.
2007 BMW 335i
Fig. 147: Removing Head Restraint

Unclip PLUG CONNECTION (1) for crash-active headrest from holder.
Fig. 148: Removing Plug Connection

Lever out protective cap (1).

2007 BMW 335i
Fig. 149: Identifying Protective Cap

Detach omega clip (1).
Fig. 150: Removing Omega Clip

Press latch mechanism (1) and lift out head restraint (2).
2007 BMW 335i
Fig. 151: Pressing Latch Mechanism

52 14 392 REMOVING AND INSTALLING/REPLACING FRONT LEFT OR RIGHT CRASH-

ACTIVE HEADREST (FROM 09/08) (CONVERTIBLE)

 Move head restraint towards top

 Remove BELT GUIDE
 Remove RELEASE HANDLE COVER
Unlock PLUG CONNECTION for crash-active headrest and disconnect.
Fig. 152: Unlocking Connector

2007 BMW 335i
Unclip cover (1) immediately with plastic wedge and partially detach with head restraint.
Fig. 153: Unclipping Cover Using Plastic Wedge

Feed out plug connection between backrest frame and tower trim.
Fig. 154: Feeding Out Plug Connection Between Backrest Frame And Tower Trim
Release and remove both clips.

2007 BMW 335i

NOTE: Clip mount varies from version to version.
If necessary, shorten upper clip mount.
Residual height of 3 mm permitted.
Fig. 156: Identifying Clip Mount

Measure position for new cable strap (1).
A. 110 - 115 mm
2007 BMW 335i
Fig. 157: Measuring Position For New Cable Strap

Note new cable routing.
Cable is secured only at lower clip mount.
Fasten cable to lower clip mount (1) to measured length with cable strap.
Check whether slide is closed.
Fig. 158: Identifying Clip Mount

Feed in connector and pull cable downwards through tower trim.

2007 BMW 335i
Fig. 159: Feeding In Connector And Pulling Cable Downwards Through Tower Trim
1. Feed lower cover at an angle into ring cover.
2. Clip in complete cover from top downwards.

2007 BMW 335i
Fig. 160: Feeding Lower Cover At Angle Into Ring Cover And Clipping-In Complete Cover From Top
Downwards
Installation note:
Retighten cable (1) and lock plug connection.
Keep contact surface clear for belt guide.
Fig. 161: Identifying Cable

52 14 400 REPLACING COVER FOR LEFT OR RIGHT FRONT SEAT (CONVERTIBLE)

 Remove REAR PANEL on front seat backrest
 Remove TRIM COVER FOR OUTER FITTING on front seat
2007 BMW 335i

 Remove SEAT BELT PRETENSIONER.
US/CDN front passenger seat (with OC3 mat) only:
WARNING: When replacing seat cover:

If seat cover is defective, seat cover and padding with OC3 mat must be
replaced together.
New seat cover is supplied with padding, OC3 mat and if necessary seat
heating.
When replacing padding or OC3 mat:
If OC3 mat or padding is defective, both parts must be replaced together.
IMPORTANT: The OC3 mat must be enabled after each installation operation.
 Connect BMW programming system


Only when replacing OC3 mat with padding:
OC3 mat (1) is secured on the left and right sides in the marked area with a longitudinal trim wire for
transportation.
Carefully remove adhesive tape (2).

2007 BMW 335i
Fig. 162: Identifying OC3 Mat And Adhesive Tape

Removing transportation lock:
Carefully release retainers in marked area on left and right from longitudinal trim wires (1).
IMPORTANT: Remove all remainders of retainers from padding and OC3 mat.
Fig. 163: Identifying Longitudinal Trim Wires

Lift seat cover (1) out of seat mechanism.

2007 BMW 335i

Lever welt (1) out of seat mechanism.
Fig. 165: Identifying Welt

Remove seat cover (1) with padding towards front/top.

2007 BMW 335i

Release the corresponding plug connections depending on the version and disconnect.
Pull seat cover (1) with padding forward a little and feed cable (2) out.
Fig. 167: Identifying Seat Cover And Feed Cable

Carefully detach all retainers in side area from longitudinal wires (1).
Pull trim wires (1) forward out of seat cover.
Carefully fold back seat cover and release retainers from crosswires (2).
2007 BMW 335i
Fig. 168: Identifying Trim Wires And Crosswires

Replacement only:
If necessary, cut new seat cover to size and insert trim wires.
Fig. 169: Identifying Trim Wires

Installation:
Bend new clips (2) with special tool 52 0 050.
1. Padding
2007 BMW 335i
2. Retainer
3. Trim wire in padding
4. Trim wire in cover
5. Seat cover
Fig. 170: Bending Clips With Special Tool

52 14 405 REPLACING BACKREST COVER FOR LEFT OR RIGHT FRONT SEAT

(CONVERTIBLE)
 Move head restraint towards top

 Remove SEAT SIDE AIRBAG
 Remove TRIM COVER
 Remove TRIM COVER FOR OUTER FITTING
Disengage bracing (2).
Installation:
Bracing (2) must be fitted under SIDE AIRBAG.

2007 BMW 335i
Fig. 171: Identifying Backrest Cover And Bracing


Detach backrest cover from metal retainer.
Lever out welt in marked area.

2007 BMW 335i

Lever backrest cover over attachment point (1).
Fig. 174: Identifying Attachment Point

Detach cable tie.
2007 BMW 335i
Fig. 175: Removing Backrest Cover With Padding Sideways From Backrest Frame
Release retainers on left/right.
Fig. 176: Locating Retainers On Left/Right

2007 BMW 335i
Fig. 177: Identifying Backrest Cover With Padding Retainers Mark Area
Installation:
Bend new retainer (2) with special tool 52 0 050.
1. Padding
2. Retainer
5. Backrest cover
Fig. 178: Identifying Padding, Retainer And Back-Rest Cover

Replacement only:
Pull trim wires out of backrest cover.

2007 BMW 335i
Cut new backrest cover to size and insert trim wires.
Fig. 179: Identifying Backrest Cover Cutting Dimensions

72 12 050 Removing and installing or replacing side airbag, front left or right seat


 Remove REAR PANEL
Unhook backrest cover (1) in marked area.

Unlock PLUG CONNECTION (1) and disconnect.

2007 BMW 335i
Release screw (2).
Installation:
Replace screw.
Tightening torque: 40 +/- 5 Nm.
Fig. 181: Identifying Connector And Screw

Unlock airbag module (1) in downward direction and remove sideways from backrest frame.
Fig. 182: Removing Airbag Module

Disengage welt from airbag module (1).

2007 BMW 335i
Fig. 183: Disengaging Welt From Airbag Module

Installation:
Bracing (1) must be fitted under airbag module.
Close bracing (1) of backrest cover before fitting airbag.
Feed airbag module (2) into bracing openings (1) and mount on backrest frame.
Fig. 184: Identifying Backrest Cover Bracing And Airbag Module

52 14 415 REPLACING PADDING FOR LEFT OR RIGHT FRONT SEAT (CONVERTIBLE)
REPLACE SEAT COVER FOR LEFT OR RIGHT FRONT SEAT.
52 14 420 REPLACING PADDING FOR LEFT OR RIGHT FRONT SEAT BACKREST

2007 BMW 335i
This operation is described in section on:
Replace BACKREST COVER FOR LEFT OR RIGHT FRONT SEAT.
52 14 886 REPLACING GAS CARTRIDGE FOR CRASH-ACTIVE HEADREST ON LEFT OR RIGHT

(COUPE)
IMPORTANT: The firing unit may be replaced up to 4 times.

Triggering frequency is denoted on the label on the head restraint carrier.
Labels are available as spare parts.
Starting situation:
Head restraint is in the crash position after being triggered.
NOTE: Firing unit can only be removed in the triggered state.
The complete crash-active head restraint must be replaced if the event of a head restraint fault signal and an
untriggered firer.
Lever out cover welt in marked area.
Remove cover with padding from head restraint.

2007 BMW 335i
Fig. 185: Identifying Cover Removing Areas

Unclip service flap.
Move firing unit (1) forwards and remove towards front.
Fig. 186: Removing Firing Unit

Replace firing unit.
Installation note:
Plug connection (1) must audibly snap into place.
Check firm engagement of plug connection (1) by gently pulling on connector.
Lay cable in side guide.

2007 BMW 335i

Press locking spring (1) on left and right through opening and secure with cylindrical pins (or similar).
Head restraint is unlocked.
Fig. 188: Pressing Locking Spring

IMPORTANT: This work requires a great exertion of effort!
Pull head restraint (1) at an angle downwards until it is completely in lowest position and rests on linkage.
Hold head restraint (1) in this position for the following tasks.
2007 BMW 335i
Fig. 189: Pulling Head Restraint

Clip firing unit (1) onto linkage (2).
Installation note:
Check that firing unit (1) is firmly seated on linkage.
Press firing unit (1) forwards and clip into place.
IMPORTANT: Firing unit (1) must audibly snap into place.
Fig. 190: Identifying Firing Unit

Installation note:
Visually check that firing unit is correctly seated.

2007 BMW 335i
Attach label for identification after replacement.
Clip service flap into place.
Fig. 191: Identifying Firing Unit Seating Position

52 14 886 REPLACING GAS CARTRIDGE FOR CRASH-ACTIVE HEADREST ON LEFT OR RIGHT

(CONVERTIBLE)
 Disconnect BATTERY NEGATIVE CABLE
IMPORTANT: Renewal of pyrotechnics may be carried out up to 5 times.

Triggering frequency is denoted on the sticker on the head restraint carrier.
Labels are available as spare parts.
Starting situation:
Head restraint is in the crash position after activation.
NOTE: Pyroactivator can only be removed in the triggered state.
The complete head restraint must be replaced in the event of a crash-active headrest fault message and non-
activated pyroactivator.
2007 BMW 335i
Fig. 192: Identifying Head Restraint In Crash Position After Activation

Removing cover:
Raise cover (1) and pull rearwards.

Removing pyrotechnics:
Press together mounting (1) for pyrotechnics at tabs.
Feed out pyrotechnics.

2007 BMW 335i
Fig. 194: Removing Pyrotechnics

Removing pyroactivator:
Pull pyroactivator (2) out of mount (1) for pyrotechnics.
Unlock PLUG CONNECTION (3) and disconnect.
IMPORTANT: Dispose of plastic element and pyroactivator.
Fig. 195: Removing Pyroactivator

Procedure for installing pyrotechnics
Bringing head restraint together - version without button (multifunction seat):
Pull apart spring catches and push together head restraint.
Maintain position.
2007 BMW 335i
Fig. 196: Bringing Head Restraint Together - Version Without Button (Multifunction Seat)
Bringing head restraint together - version with button (basic version):
Press button (1) and push head restraint together.
Maintain position.
Fig. 197: Bringing Head Restraint Together - Version With Button (Basic Version)
Locking release plate:
Hold pushed-together head restraint in position and push release plate (1) upwards up to limit position.
Release plate (1) must audibly snap into place.

2007 BMW 335i
Fig. 198: Locking Release Plate

Checking head restraint lock:
Check end position of release plate (1).
All four springs must be engaged (snapped into place).
Fig. 199: Checking Head Restraint Lock

Replacing pyrotechnics:
Connect connector (1) to new pyroactivator (2) and LOCK .
Clip pyroactivator (2) into new mount (3).

2007 BMW 335i
Fig. 200: Replacing Pyrotechnics

Installing pyrotechnics:
Press together mounting for pyrotechnics at tabs.
Insert mounting for pyrotechnics into release plate and tilt in upward direction.
Mounting for pyrotechnics must audibly snap into place.
NOTE: Check seating of retaining lugs in mounting.
Fig. 201: Installing Pyrotechnics

Laying wiring harness:
Secure wiring harness in support section with strain relief.

2007 BMW 335i
Fig. 202: Laying Wiring Harness

Mounting cover:
Clip cover onto support section.
Cover must audibly snap into place.
Fig. 203: Mounting Cover

FRONT SEAT, SPORTS, MANUAL

52 15 050 REMOVING AND INSTALLING/REPLACING THIGH SUPPORT ON LEFT OR RIGHT
FRONT SEAT (SPORT/MANUAL) (COUPE)
Release thigh support (1) and move forward.
Lever welt (3) of seat cover (2) out of thigh support (1).
2007 BMW 335i
Fig. 204: Identifying Thigh Support, Welt And Seat Cover

Do not extend thigh support to its full extent.
Keep actuator (1) pressed in order to unlock centering element (2).
Carefully raise end stop (3) for thigh support with a screwdriver and at same time pull thigh support forwards
out of guide rails.
Fig. 205: Identifying Actuator, Centering Element And End Stop

View of thigh support mechanism:
1. End stop for thigh support

2. Locking mechanism for thigh support
2007 BMW 335i
Fig. 206: Identifying End Stop And Thigh Support locking Mechanism
View of seat frame mechanism:
3. Guide rail on seat with depth arrester

4. Guide rail on seat with end stop
Fig. 207: Identifying Depth Arrester And End Stop Guide Rails
NOTE: Check guide rails (2) and adjustment mechanism (3) for damage.
2007 BMW 335i
Fig. 208: Identifying Plug Connection, Guide Rails And Adjustment Mechanism
52 15 055 REMOVING AND INSTALLING/REPLACING LUMBAR CUSHION ON FRONT SEAT

(COUPE)

Unlock quick connector and detach air hoses (1 and 2) from valve housing (3).

2007 BMW 335i
Fig. 210: Identifying Air Hoses And Valve Housing

Detach lumbar cushion (1) from spring wire (2).
Installation:
Attach lumbar support (1) to third and fifth wires from below.
Unclip air hoses (3) and (4) from holder.
Fig. 211: Identifying Lumbar Cushion, Spring Wire And Air Hoses
Press back support (1) a little.
Pull lumbar support (2) up and out.
Feed air hoses out of backrest frame and spring wire.

2007 BMW 335i
Fig. 212: Identifying Back And Lumbar Supports

Installation:
Check lumbar support at top (1) and bottom (2) for damage.
Air hoses (3) must not be kinked.
Fig. 213: Identifying Air Hoses, Top And Bottom Lumbar Support
Installation:
Carry out Function Check.function check.
52 15 057 REMOVING AND INSTALLING / REPLACING VALVE HOUSING FOR LUMBAR

SUPPORT / BACKREST WIDTH ADJUSTMENT (COUPE)

2007 BMW 335i

Remove valve housing in direction of arrow from backrest frame.
1. Valve housing for backrest width adjustment.

2. Valve housing for lumbar support.
Installation:
Fig. 215: Identifying Backrest Width Adjustment And Lumbar Support Valve Housings

2007 BMW 335i
(3) Hose (black), lumbar drive

Valve unit for backrest width adjustment:
Fig. 216: Identifying Valve Housing, Plug Connection, Lock Quick Connector And Air Hoses
(4) Hose (clear), left lumbar cushion

(5) Hose (clear), right lumbar cushion
52 15 060 REPLACING AN AIR CUSHION FOR LEFT OR RIGHT BACKREST WIDTH

ADJUSTMENT (COUPE)

2007 BMW 335i

NOTE: Removal of the cushion on the left side is depicted; proceed in the same way
for the right side.
Air cushion must be completely drained.
Disconnect spring (1).
Lever out clips with plastic wedge.
Feed out air cushion (2) between spring wire and backrest frame.
Fig. 218: Identifying Air Cushion And Spring

Installation:
Insert air cushion without kinks.
Check air cushion for damage.

2007 BMW 335i
If necessary, remove Valve Housing
Installation:
Connections are coded against incorrect assembly.
Air hoses must not be kinked.
Fig. 219: Identifying Air Hoses And Valve Housing

NOTE: Carry out Operational Check.
52 15 403 REMOVING AND INSTALLING/REPLACING THIGH SUPPORT COVER ON FRONT

SEAT (SPORT/MANUAL) (COUPE)
Lever welt of seat cover (2) out of thigh support.

2007 BMW 335i
Fig. 220: Identifying Thigh Support And Seat Cover Welt

Lever out cover welt in marked area (1).
Disengage trim thread in marked area (2) from thigh support.
Remove cover with padding.
Fig. 221: Identifying Marked Areas

Pull cover (1) off padding (2).

2007 BMW 335i
Fig. 222: Identifying Cover And Padding

52 15 415 REPLACING PADDING FOR LEFT OR RIGHT FRONT SEAT (SPORT/MANUAL)

(COUPE)
Replacing Seat Cover On Left Or Right Front Seat.
52 15 417 REPLACING PADDING FOR LEFT OR RIGHT THIGH SUPPORT (SPORT/MANUAL)

(COUPE)
Replacing Thigh Support Cover On Left Or Right Front Seat.
52 15 420 REPLACING PADDING FOR LEFT OR RIGHT FRONT SEAT BACKREST

(SPORT/MANUAL) (COUPE)
Replacing Backrest Cover For Left Or Right Front Seat.
52 15 455 REPLACING HEATING ELEMENTS FOR LEFT OR RIGHT FRONT SEAT (SPORT /
MANUAL) (COUPE)
 Remove Seat Fabric

 Remove Backrest Cover
 Remove Thigh Support Cover
2007 BMW 335i
NOTE: Heating elements are bonded with a foam section and cannot be separated from
each other without causing damage.
Foam section and heating elements must be replaced.
Check new foam section:

 All trim wires present in foam
 No bubbles in foam section
 No dirt/contamination on foam or residual foam
 Pay attention to foam section on left and right
Check new heating mat:

 All tear-off film pieces presents
 Note variant by examining label on cable
Guide cable for backrest heating through foam hole.

2007 BMW 335i
Guide cable for seat heating through foam hole.
Stick on STV heating mat (1):
 Pull off adhesive film and stick to rear foam edge until flush
Fig. 224: Identifying STV Heating Mat, Main Section And Bead Section
Check laying of heating mats:
 Heating mats laid without folds

 Heating mats correctly positioned
 All bonding surfaces stuck on
FRONT SEAT, SPORTS, ELECTRIC

52 16 040 REMOVING AND INSTALLING OR REPLACING OUTER COVERS ON LEFT OR
RIGHT FRONT SEAT (CONVERTIBLE)
Move seat upwards.

2007 BMW 335i
Lever out tabs (2) at bottom.
Unclip cover (1) at top and detach cover from carrier section.
Unfasten plug connection and disconnect.
Fig. 225: Identifying Cover And Bottom Tabs

Replacement only:
Carefully raise retainers and remove switch cluster.
Installation:
Tabs and retainers must not be damaged.
Fig. 226: Locating Tabs And Retainers

2007 BMW 335i
52 16 048 REMOVING AND INSTALLING THIGH SUPPORT ON LEFT OR RIGHT FRONT SEAT
(SPORT/ELECTRIC) (COUPE)
Fig. 227: Identifying Seat Cover, Welt And Thigh Support

out of guide rails.
2007 BMW 335i
Fig. 228: Identifying Actuator, Centering Element And End Stop

Fig. 229: View Of Thigh Support Mechanism

2007 BMW 335i
Fig. 230: View Of Seat Frame Mechanism

Fig. 231: Identifying Guide Rails, Plug Connection And Mechanism

52 16 048 REMOVING AND INSTALLING THIGH SUPPORT ON LEFT OR RIGHT FRONT SEAT
(CONVERTIBLE)
2007 BMW 335i
Release thigh support and move forward.
Lever welt (1) of seat cover out of thigh support.

Turn thigh support (1) over.
Detach trim wire from metal lugs.
Fig. 233: Identifying Thigh Support


2007 BMW 335i
Fig. 234: Identifying Spring

Release screws (1).

Release thigh support and pull forward to remove from seat mechanism.

2007 BMW 335i
Fig. 236: Locking Mechanism For Thigh Support

52 16 050 REMOVING AND INSTALLING OR REPLACING THIGH SUPPORT ON LEFT OR

RIGHT FRONT SEAT (SPORT/ELECTRIC) (COUPE)
Fig. 237: Identifying Thigh Support, Welt And Seat Cover

2007 BMW 335i
Fig. 238: Identifying Lever Welt Of Seat Cover

out of guide rails.

2007 BMW 335i
Fig. 239: Identifying End Stop For Thigh Support


Fig. 240: Identifying Guide Rail On Seat With Depth Arrester

2007 BMW 335i
Fig. 241: Identifying Guide Rails And Adjustment Mechanism

52 16 050 REMOVING AND INSTALLING OR REPLACING LUMBAR CUSHION ON FRONT SEAT

(CONVERTIBLE)
Disconnect plug connection (1) at drive unit.


2007 BMW 335i

Lift fleece tabs of lumbar support cushion carrier from plastic clips (1).
Installation:
Hook lumbar support cushion over first and fourth wire.
Fig. 244: Identifying Plastic Clips

Detach lumbar cushion (2) from spring wire.
Unclip air cushion (1) for backrest width adjustment with carrier from backrest frame.
Installation:
Make sure the carrier for backrest width adjustment is fitted correctly on the backrest frame.
2007 BMW 335i
Fig. 245: Identifying Lumbar Cushion And Air Cushion

Fig. 246: Identifying Air Cushion And Valve Housing

Disconnect air hoses to remove corresponding components.
If tight, (carefully) heat up the parting points slightly.
Installation:
Check lumbar cushion at top (1) and bottom (2) for damage.
Lay air hoses (3) without kinks.

2007 BMW 335i
Fig. 247: Identifying Lumbar Cushion Top And Bottom And Air Hoses
Installation:
Carry out FUNCTION CHECK.

ADJUSTMENT (COUPE)
 Remove rear panel on front seat
Fig. 248: Identifying Backrest Cover From Backrest Frame

NOTE: Removal of the cushion on the left side is depicted; proceed in the same way
2007 BMW 335i
for the right side.

Air cushion must be completely drained.
Fig. 249: Removing Air Cushion Between Spring Wire And Backrest Frame
Lever out clips with plastic wedge.
Feed out air cushion (2) between spring wire and backrest frame.
Installation:
Insert air cushion without kinks.
Check air cushion for damage.
If necessary, remove valve housing.
Installation:
Connections are coded against incorrect assembly.
Air hoses must not be kinked.

2007 BMW 335i
Fig. 250: Identifying Lock Quick Connector And Valve Housing

NOTE: Carry out operational check.

 Remove REAR PANEL ON FRONT SEAT

Unclip carrier for backrest width adjustment from backrest frame.
Installation:
Make sure the carrier for backrest width adjustment is fitted correctly on the backrest frame.
Install air hoses without kinks.

2007 BMW 335i
Fig. 251: Identifying Backrest Width Adjustment

Disconnect air hoses.
Installation:
Adapt length of air hose from new part.
Connect air hoses to brass coupling.
If tight, (carefully) heat up the air hoses slightly.
Fig. 252: Identifying Air Hoses

NOTE: Carry out FUNCTION CHECK.

2007 BMW 335i

CUSHION (COUPE)
 Remove rear panel on front seat

Remove valve housing (2) for lumbar support in direction of arrow from backrest frame.
Installation:

2007 BMW 335i
Fig. 254: Identifying Valve Housing From Backrest Frame


Fig. 255: Identifying Back Support

NOTE: Carry out function test

CUSHION (CONVERTIBLE)
NOTE: Operation is described in:
 Removing and installing lumbar support cushion on front seat
52 16 400 REPLACING SEAT COVER FOR LEFT OR RIGHT FRONT SEAT (SPORTS/ELECTRIC)
(COUPE)

2007 BMW 335i
 52 0 050

 Remove Rear Panel on front seat
 Remove Thigh Support
Unlock retaining lugs (1).
Remove seat trim (2) downwards.
Installation:
Seat trim (2) must not be damaged.
Fig. 256: Identifying Retaining Lugs And Seat Trim

Unlock plug connection (1) for seat heating and disconnect.
2007 BMW 335i

Release screw (1).
Installation:
Fig. 258: Identifying Seat Cover Clip, Trim And Screw

Detach seat cover (1) from seat frame.

2007 BMW 335i
Fig. 259: Detaching Seat Cover From Seat Frame

Pull out cover welt (1) completely from seat frame (2).
Fig. 260: Identifying Cover Welt And Seat Frame

Remove seat cover (1) towards front/top.

2007 BMW 335i

Version with seat heater and/or with seat occupancy detector:
Pull seat cover (1) with padding forward a little and feed wiring harness (2) out.
Remove seat cover (1) towards front/top.
Fig. 262: Identifying Seat Cover And Wiring Harness


2007 BMW 335i
Fig. 263: Identifying Seat Cover In Marked Area

NOTE: Remove all remnants of clips from seat cover and padding.
Fig. 264: Identifying Seat Cover And Padding

Installation:
Bend new retainers (2) closed with special tool 52 0 050
1. Padding
2. Retainer
2007 BMW 335i
4. Trim thread in cover

5. Seat cover
Fig. 265: Identifying Padding, Trim, Seat Cover, Retainers And Special Tool (52 0 050)
Pull trim threads out of seat cover.
Cut new seat cover to size and insert trim threads.

52 16 400 REPLACING SEAT COVER FOR LEFT OR RIGHT FRONT SEAT (SPORTS/ELECTRIC)
(CONVERTIBLE)

 Remove CARRIER OF OUTER COVER
2007 BMW 335i

 Remove SEAT BELT PRETENSIONER
US/CDN front passenger seat (with OC3 mat) only:
WARNING: When replacing seat cover:

If seat cover is defective, seat cover and padding with OC3 mat must be
replaced together.
New seat cover is supplied with padding, OC3 mat and if necessary seat
heating.
When replacing padding or OC3 mat:
If OC3 mat or padding is defective, both parts must be replaced together.
IMPORTANT: The OC3 mat must be enabled after each installation operation.
 Connect BMW programming system


Only when replacing OC3 mat with padding:
OC3 mat (1) is secured on the left and right sides in the marked area with a longitudinal trim wire for
transportation.
Carefully remove adhesive tape (2).

2007 BMW 335i
Fig. 267: Identifying OC3 Mat And Adhesive Tape

Removing transportation lock:
Carefully release retainers in marked area on left and right from longitudinal trim wires (1).
IMPORTANT: Remove all remainders of retainers from padding and OC3 mat.
Fig. 268: Identifying Longitudinal Trim Wires

Remove seat panel.

2007 BMW 335i
Fig. 269: Identifying Seat Panel Screws



2007 BMW 335i

Unfasten thigh support and pull completely towards front.
Lever welt (1) out of thigh support.

Turn thigh support (1) over.
Detach trim wire from metal lugs.

2007 BMW 335i
Fig. 273: Identifying Thigh Support

Pull seat cover (1) with padding forward a little and feed cable (2) out.
Fig. 274: Identifying Seat Cover And Wiring Harness

Release all retainers in marked areas.

2007 BMW 335i
Fig. 275: Identifying Retainers In Marked Areas

Detach all retainers in side area from longitudinal welts (1).
Carefully turn seat cover over and release retainers from crosswelt (2).
Fig. 276: Identifying Longitudinal Welts And Crosswelt

Replacement only:
Pull trim wires (1) out of seat cover (2).

2007 BMW 335i
Installation:
If necessary cut hole in new seat cover for trim wires.
Insert trim wires.
(3) Seat heater cable
Fig. 277: Identifying Trim Wires And Seat Cover

Installation:
Insert new retainer (2) with special tool 52 0 050 and bend closed.
1. Padding
2. Retainer
4. Trim wire in seat cover
5. Seat cover
2007 BMW 335i
Fig. 278: Bending Retainers Closed With Special Tool

52 16 405 REPLACING BACKREST COVER ON FRONT LEFT OR RIGHT SEAT

(SPORTS/ELECTRIC)
 52 0 050

 Remove Cover For Release Mechanism
Detach cable strap (2).
Release wiring harness from cable holders on seat mechanism.
2007 BMW 335i
Fig. 279: Identifying Plug Connection And Cable Strap



2007 BMW 335i
Fig. 281: Detaching Backrest Cover In Marked Area


2007 BMW 335i
Fig. 283: Identifying Backrest Cover Retainers

Installation:
Bend new retainer (2) with special tool 52 0 050
1. Padding
2. Retainer
5. Back-rest cover
Fig. 284: Identifying Padding, Trim, Backrest Cover, Retainers And Special Tool (52 0 050)
Replacement of backrest cover:
Pull trim threads out of backrest cover.

2007 BMW 335i
Cut new backrest cover to size and insert trim threads.
Fig. 285: Identifying Trim Threads Of Backrest Cover

REAR SEAT NORMAL

52 24... EMERGENCY ACTUATOR FOR REAR SEAT BACKREST
1. Release hook of backrest lock

2. Backrest
Fig. 286: Identifying Backrest And Backrest Lock Release Hook

Insert screwdriver for levering in snap-in hole of rear seat lock.
Press screwdriver to center of vehicle and in so doing press supporting point (1) of Bowden cable outwards
2007 BMW 335i
Fig. 287: Identifying Bowden Cable Supporting Point

52 24... REMOVING AND INSTALLING/REPLACING CUP HOLDER IN ARMREST FOR REAR

SEAT BACKREST
Open armrest.
Open cup holder.
Remove complete cup holder towards front.

52 24... REPLACING LEFT OR RIGHT GUIDE SLEEVES

2007 BMW 335i
 Remove AIR OUTLET TRIM GRILLE
Unlock guide sleeves (1) and remove towards top.
Fig. 289: Identifying Guide Sleeves

52 24 000 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT REAR SEAT

(CONVERTIBLE)
Unclip left or right rear seat towards top.
Raise rear seat approx. 30 cm and remove towards front.
Installation:
Feed seat belt buckles (1) into openings in rear seat.
Fig. 290: Identifying Seat Belt Buckles

2007 BMW 335i
Installation:
Insert pin on rear seat (1) correctly into opening in rest side section (2).
Pin must not be damaged.
Fig. 291: Identifying Rear Seat And Side Section

52 24 008 REMOVING AND INSTALLING OR REPLACING LEFT OR RIGHT SIDE SECTION ON

REAR SEAT BACKREST (CONVERTIBLE)
 Remove REAR SEAT

 Release rear-seat backrest and fold forward.
Removing rest side section:
1. Unclip in middle
2. Lever out at top from belt cover
3. Lift out rest side section
2007 BMW 335i
Fig. 292: Identifying Rest Side Section

Installation:
Unlock clip (1) and pull forwards out of body.
Engage clip (1) in rest side section.
If necessary, replace faulty clip (1).
Fig. 293: Identifying Clip

Installation:
Insert rest side section under backrest mount (2).
Insert plastic tab (1) of rest side section in backrest mount (2).
Pin must not be damaged.

2007 BMW 335i
Fig. 294: Identifying Plastic Tab And Backrest Mount

52 24 010 REMOVING AND INSTALLING / REPLACING BACKREST (CONVERTIBLE)
 Remove BACKREST SIDE SECTION
Release backrest and fold down.
Release screws (1) on backrest.
Remove backrest.
Fig. 295: Identifying Screws On Backrest

52 24 030 REMOVING AND INSTALLING COMPLETE ARMREST (FILLER ELEMENT) FOR

REAR SEAT BACKREST (CONVERTIBLE)
Press lock (1) and remove filler element (2).

2007 BMW 335i
Installation:
Make sure filler element is correctly inserted in rear seat backrest.
Fig. 296: Identifying Lock And Filler Element

52 24 045 REMOVING AND INSTALLING OR REPLACING BACKREST FRAME (CONVERTIBLE)
 Remove BACKREST COVER

 Remove LOCKING UNIT
52 24 300 REMOVING AND INSTALLING OR REPLACING LOCKING UNIT AT BACKREST

(BACKREST FRAME RELEASE)
Release screws (1).
Remove locking unit.

2007 BMW 335i
Fig. 297: Locating Locking Unit Screws

52 24 390 REMOVING AND INSTALLING OR REPLACING LEFT OR RIGHT REAR HEAD

RESTRAINT (CONVERTIBLE)
 Unlock backrest and tilt forward
Pull head restraint out of guide sleeves by moving backwards and forwards.
Fig. 298: Identifying Head Restraint

52 24 400 REPLACING SEAT COVER FOR REAR SEAT
 52 0 050
2007 BMW 335i
Unclip Isofix protective caps.
Installation:
Make sure Isofix protective caps are correctly engaged.
Fig. 299: Identifying Isofix Protective Caps

Lever out welt in area (1) with plastic wedge.
Unhook seat cover in area (2).
Unclip welt (3) from seat pan
Fig. 300: Identifying Welt Area, Seat Cover Area And Welt
2007 BMW 335i
Detaching cover and padding:
 Release all retainers in marked area.

 Remove seat cover from padding.
 Remove remaining retainers from cover and padding
Fig. 301: Identifying Retainers In Marked Area

Installation:
Insert new retainer (2) with special tool 52 0 050 and bend closed.
1. Padding
2. Retainer
4. Trim thread in seat cover
5. Seat cover
2007 BMW 335i
Fig. 302: Identifying Padding, Threads, Seat Cover, Retainer And Special Tool (52 0 050)
Replacing cover:
 Pull all trim wires out of seat cover

 If necessary, cut in take-up for trim wires of new cover
 Push trim wires into new seat cover
Fig. 303: Locating Trim Wires In Seat Cover

52 24 408 REPLACING LEFT BACKREST COVER FOR REAR SEAT (CONVERTIBLE)
 Remove left backrest cover
Unclip trim cover (1) for released button on left and right.
2007 BMW 335i
Installation:
If necessary, replace faulty trim.

Release screw (1).
Push through plastic pins.
Fig. 305: Identifying Screw And Plastic Pins

Unscrew nut (1).
Remove outer mount (2).

2007 BMW 335i
Fig. 306: Identifying Nut And Outer Mount

Lever out welt from backrest cover all round with plastic wedge.
Fig. 307: Identifying Welt And Plastic Wedge

 Release all retainers in marked area

 Remove cover from padding
2007 BMW 335i
Fig. 308: Identifying Retainers Marked Area

Installation:
Insert new retainer (2) with special tool 52 0 050.
In so doing, enclose wire in padding and trim wire of cover and bend closed.
1. Padding
2. Retainer
4. Trim wire in seat cover
5. Seat cover
Fig. 309: Inserting Retainer With Special Tool

Replacing cover:
2007 BMW 335i
 Remove all trim wires from cover

 If necessary, cut pockets in new cover for trim wires
 Push trim wires into cover pockets
Fig. 310: Identifying Trim Wires

52 24 455 REPLACING PADDING FOR REAR SEAT
Replacing SEAT COVER FOR REAR SEAT
REAR SEAT, THROUGH-LOADING

52 26... REMOVING AND INSTALLING/REPLACING ALL GUIDE SLEEVES FOR REAR HEAD
RESTRAINTS (COUPE)
 52 0 070
 Remove Head Restraint from rear seat
NOTE: Guide sleeves cannot be removed without being damaged.
Guide sleeves with locks have two retaining lugs.
Insert special tool 52 0 070 into guide hole of sleeve (2) up to upper area of retaining lug.
Feed release tongue of special tool in to rear gap on retaining lug (1).
2007 BMW 335i
Turn tool to release sleeve (2) and pull out towards top.
On guide sleeves with locks, unlock the second retaining lug with a screwdriver.
Fig. 311: Identifying Release Sleeve, Lugs And Special Tool (52 0 070)
52 26... REMOVING AND INSTALLING/REPLACING CUP HOLDER IN ARMREST FOR REAR

SEAT BACKREST (COUPE)
Open armrest.
Open cup holder.
Remove complete cup holder towards front.
Fig. 312: Identifying Cup Holder Screw

2007 BMW 335i
52 26... REMOVING AND INSTALLING/REPLACING SKI BAG WITH CASING ON REAR SEAT
(THROUGH-LOADING SYSTEM) (COUPE)
 Remove center armrest or

 filler element
Press ski bag (1) on rear side out of backrest.
Fig. 313: Pressing Ski Bag On Rear Side Out Of Backrest

Lift off cover (1).
Release screws (2).
Installation:
Make sure cover is correctly installed.

2007 BMW 335i

Unclip single opening trim (1) towards top.
Installation:
Plastic clips must not be damaged.
If necessary, replace faulty trim.
Fig. 315: Identifying Opening Trim And Plastic Clips

Remove C-module trim (1) in direction of arrow.

2007 BMW 335i
Fig. 316: Identifying C-Module Trim And Removal Direction

52 26 000 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT REAR SEAT

(THROUGH-LOADING) (COUPE)
 Remove Filler Element
Unclip left or right rear seat in upward direction.
Installation:
Feed seat belt buckles (1) into openings in rear seat.

2007 BMW 335i
Fig. 317: Identifying Seat Belt Buckles

52 26 008 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT SIDE SECTION ON

REAR SEAT BACKREST (COUPE)
Release rear-seat backrest and fold forward.
Pull seat belt to middle and place over head restrain t.
Pull top backrest side section forwards (1) and pull out towards top (2).
Fig. 318: Identifying Top Backrest Side Section Removal Directions

If necessary, replace faulty clip (2) from backrest side section:
Unlock catches (1) on left and right and detach clip (2) from side section (3).
2007 BMW 335i
Fig. 319: Identifying Side Section, Catches And Clip

If necessary, replace faulty clip (1) from body:
Pull clip (1) forwards out of body.
Fig. 320: Identifying Clip And Removal Direction

Installation:
Push guide (1) into mounting (2) and guide (3) into mounting (4).
2007 BMW 335i
Fig. 321: Identifying Guides And Mountings

52 26 015 REMOVING AND INSTALLING/REPLACING BACKRESTS FOR LEFT OR RIGHT

REAR SEAT (COUPE)
NOTE: This operation is described in:
 Removing and installing both Backrests For Rear Seat
52 26 020 REMOVING AND INSTALLING/REPLACING BOTH BACKRESTS FOR REAR SEAT

(COUPE)
 Remove Armrest Side Section

NOTE: A 2nd person is required to help remove and install the backrest.
Both backrests must be pulled out simultaneously from the center mount.
Left backrest:
 Release screw (1).
For tightening torque refer to 1AZ in 52 26 REAR SEATS (THROUGH-LOADING SYSTEM) .
 Fold backrest (2) forwards

 Pull backrest forwards and outwards out of center mount (3)
2007 BMW 335i
Fig. 322: Identifying Centre Mount, Left Backrest And Screw

Right backrest:
 Release screw (1).
 Fold backrest (2) forwards

 Pull backrest forwards and outwards out of center mount (3)
Fig. 323: Identifying Centre Mount, Right Backrest And Screw

52 26 030 REMOVING AND INSTALLING COMPLETE CENTER ARMREST FOR REAR SEAT
BACKREST (THROUGH-LOADING) (COUPE)
Unlock right backrest and tilt forwards.

2007 BMW 335i
Release screw.
Open center armrest (1) and remove.
Fig. 324: Identifying Centre Armrest And Screw

Version "without skibag" only
Pull cover trim (1) at top edges in stages and unclip.
Installation:
Clips may remain in the backrest frame and must be removed.

2007 BMW 335i
Fig. 325: Identifying Centre Armrest Cover Trim

NOTE: Forcefully pull top edge of cover trim (3) forwards and unclip upper retaining
lug (1).
Unclip the four retaining lugs (2) in succession.
Fig. 326: Identifying Cover Trim And Retaining Lugs

Pull cover trim (1) up and out of lower clips.
Installation:
Make sure cover trim (1) is correctly inserted into lower clips.
Fig. 327: Identifying Cover Trim And Mounting Clips

2007 BMW 335i
NOTE: Twist cover trim (1) out of lower retaining lug during removal.
Cover trim (1) must be replaced if retaining lugs are faulty.
Fig. 328: Identifying Cover Trim, Lower Retaining Lugs And Trim Removal Direction
Remove cover strip (1) from backrest frame.
NOTE: Cover strip (1) must be replaced if retaining lugs are faulty.
Fig. 329: Identifying Retaining Lugs, Cover Strip And Backrest Frame
52 26 070 REMOVING AND INSTALLING/REPLACING FILLER ELEMENT (COUPE)
Reach between filler element (1) and backrest.
Unclip filler element (1) towards front and lift out.

2007 BMW 335i
Fig. 330: Identifying Filler Element And Backrest

Installation:
Insert filler element behind guide of rear seat.
Press down filler element firmly.
Metal eyelet must snap noticeably and audibly into place on retaining clip (1).
Fig. 331: Identifying Retaining Clip And Filler Element

52 26 080 REMOVING AND INSTALLING/REPLACING LEFT BACKREST FRAME FOR REAR

SEAT (COUPE)

2007 BMW 335i
52 26 085 REMOVING AND INSTALLING/REPLACING RIGHT BACKREST FRAME FOR REAR

SEAT (COUPE)
52 26 199 REMOVING AND INSTALLING/REPLACING REAR PANEL ON LEFT REAR SEAT

BACKREST (COUPE)
 Remove Backrest For Rear Seat

 Remove Cover Strip or
Remove Ski Bag
Lever backrest cover all round out of backrest frame.
Fig. 332: Levering Backrest Cover Out Of Backrest Frame

Detach rear panel (2) with flat scraper (1) from rear seat backrest.
Installation:
Comply with instructions issued by manufacturer of universal spray adhesive.
Apply universal spray adhesive to rear panel and rear seat backrest.
Fit and align rear panel within the air drying time.
Observe and adhere to curing time to prevent rear panels from slipping.
2007 BMW 335i
Fig. 333: Identifying Rear Panel And Flat Scraper

52 26 200 REMOVING AND INSTALLING/REPLACING REAR PANEL ON RIGHT REAR SEAT

BACKREST (COUPE)
 Removing and installing/replacing Rear Panel On Left Rear Seat Backrest.
52 26 303 REMOVING AND INSTALLING/REPLACING ACTUATOR FOR LEFT OR RIGHT REAR

SEAT BACKREST (THROUGH-LOADING SYSTEM) (COUPE)
 00 9 317
Unclip Bowden cable (1).
Unlock catch (3) to center of vehicle and at same time unclip actuator (4) towards bottom.
If necessary, unclip actuator (4) with special tool 00 9 317

2007 BMW 335i
Fig. 334: Identifying Clip Bowden Cable, Catch, Actuator And Screws
Installation:
Catches (1) and (2) of actuator (3) must not be damaged.
Bowden cable (4) must be correctly engaged in actuator (3).
Fig. 335: Identifying Catches, Actuator And Bowden Cable

52 26 311 REMOVING AND INSTALLING/REPLACING LOCK FOR LEFT OR RIGHT REAR SEAT
BACKREST (THROUGH-LOADING SYSTEM) (COUPE)
Unlock rear seat backrest and fold down.
NOTE: In event of faulty unlocking, perform Emergency Opening.
Unclip Bowden cable from holders (1).

2007 BMW 335i
Fig. 336: Identifying Screws And Bowden Cable Holder

Pull lock (1) out of installation opening slightly and unclip Bowden cable (2).
Remove lock completely from installation opening.
Installation:
Catches (2) on lock must not be damaged.
Bowden cable must be correctly anchored in catches (2).
Fig. 337: Identifying Catches, Lock And Bowden Cable

2007 BMW 335i
Installation:
Slide guide lug (1) of lock into opening (2).
Fig. 338: Identifying Slide Guide Lugs And Opening

Adjusting lock:
 Slacken screws
 Firmly push engaged backrest back
 Tighten down screws
52 26 390 REMOVING AND INSTALLING OR REPLACING LEFT OR RIGHT REAR HEAD

RESTRAINT (COUPE)
 Unlock backrest and tilt forward
Move head restrain t (1) upwards to maximum extent.
Press lock (2) and pull out head restraint.

2007 BMW 335i
Fig. 339: Identifying Lock And Head Restraint

52 26 411 REPLACING LEFT BACKREST COVER FOR REAR SEAT (COUPE)
 52 0 050
 Remove left Backrest Cover

 Remove Centre Armrest and
if necessary Ski Bag
Release screw (1).

2007 BMW 335i
Fig. 340: Identifying Screws And Outer Mount

Lever out backrest cover all round with plastic wedge or screwdriver.
Fig. 341: Levering Out Backrest Cover

Lever cover with trim wires (1) out of metal claws (2) all round from skibag opening.
Remove backrest cover with padding from carrier section.

2007 BMW 335i
Fig. 342: Identifying Lever Cover With Trim Wires


 Remove cover from padding.
Fig. 343: Identifying Cover Retainers In Marked Area

Installation:
Insert new retainer (2) with special tool 52 0 050
1. Padding
2007 BMW 335i
2. Retainer
5. Seat cover
Fig. 344: Identifying Retainer, Padding, Retainer, Trim Thread, Seat Cover And Special Tool (52 0
050)
Replacing cover:

Fig. 345: Identifying Trim Wires In Cover Pockets

52 26 412 REPLACING RIGHT BACKREST COVER FOR REAR SEAT (COUPE)

2007 BMW 335i
 00 9 317
 52 0 050
 Remove Right Backrest

Release screw (1).
Fig. 346: Identifying Screws And Outer Mount

Lever out backrest cover all round with special tool 00 9 317 or screwdriver.
Remove backrest cover with padding from carrier section.

2007 BMW 335i
Fig. 347: Identifying Out Backrest Cover And Special Tool (00 9 317)

 Remove cover from padding.
Fig. 348: Removing Retainers In Marked Areas

Installation:
Insert new retainer (2) with special tool 52 0 050
1. Padding
2007 BMW 335i
2. Retainer
5. Seat cover
Fig. 349: Identifying Retainer, Padding, Trim Threads, Seat Cover And Special Tool (52 0 050)
Replacing cover:

Fig. 350: Inserting Trim Wires Into Cover Pockets

52 26 455 REPLACING PADDING FOR REAR SEAT (COUPE)

2007 BMW 335i
 Replacing Seat Cover For Rear Seat

2007 BMW 335i
2007 SPECIFICATIONS INDEX 335i - Coupe/Convertible
2007 SPECIFICATIONS INDEX
335i - Coupe/Convertible
SPECIFICATIONS INDEX
335i SPECIFICATIONS INDEX
System Specification/Procedure
Air Conditioning
Service TECHNICAL DATA
Torque TIGHTENING TORQUES
Axle Nut/Hub Nut (Collar Nut)
Front WHEEL BEARINGS AND STUB AXLE
Rear WHEEL BEARINGS
Battery BATTERY
Brakes
Bleeding Sequence BRAKE TESTING AND BLEEDING
Disc Brakes TECHNICAL DATA
Charging
Generator R&I ALTERNATOR WITH DRIVE
Torque ALTERNATOR WITH DRIVE
Drive Belts
Adjustment V-RIBBED BELT WITH TENSIONER
Belt Routing V-RIBBED BELT WITH TENSIONER
Engine Cooling
General Service Specifications NA
Radiator Cap Pressure TECHNICAL DATA
Thermostat R & I THERMOSTAT AND CONNECTION
Water Pump R & I WATER PUMP WITH DRIVE
Engine Mechanical
Compression ENGINE, GENERAL
Oil pressure Oil pressure at idle speed with engine at
operating temperature: 22 psi (152 min
kPa); regulated pressure: 58-87 psi (400-600
kPa)
Overhaul TECHNICAL DATA
Torque TORQUE SPECIFICATIONS
Fluid Specifications See FLUIDS under MAINTENANCE tab.
From within Manager or Service Writer, click
the "30/60/90 Interval" or "Maint." button.
Flywheel/Flex Plate Torque FLYWHEEL
2007 BMW 335i
2007 SPECIFICATIONS INDEX 335i - Coupe/Convertible
Fuel System
Fuel Filter Location In Tank
Fuel Filter R & I REMOVING AND INSTALLING OR
REPLACING FUEL FILTER WITH
PRESSURE REGULATOR
(PETROL/GASOLINE)
Pressure Release Procedure NA
Pressure Specification 72 psi (496 kPa)
Fuel Pressure Test Procedure NOTES ON FUEL PRESSURE CHECK
(REFERENCE PRESSURE:
ENVIRONMENT)
Ignition
Firing Order FIRING ORDER & CYLINDER
INDENTIFICATION
Ignition Wires (Routing) Coil on plug
Spark Plug
Type NGK ZGR6STE2
Gap Not Adjustable
Torque 23 Ft. Lbs. (31 N.m)
Starting
Starter NA
Torque STARTER WITH MOUNTING
Wheel Alignment
Adjustment Specifications TECHNICAL DATA
Wheel & Tire
Wheel Lug Nut Torque 81-96 Ft. Lbs. (110-130 N.m)
2007 BMW 335i
SUSPENSION Steering and wheel alignment - Repair Instructions
SUSPENSION
Steering and wheel alignment - Repair Instructions
ELECTRONIC CHASSIS ALIGNMENT

STOP FUNCTION (MSA)

31 33... MEASURING RIDE-LEVEL HEIGHT OF VEHICLE
Fig. 1: Ride-Level Height Of Vehicle

32... OVERVIEW OF STEERING

2007 BMW 335i
Fig. 2: Overview Steering Components And Assembly

32... OVERVIEW OF STEERING (AWD)

2007 BMW 335i
Fig. 3: Overview Of Steering (AWD)

2007 BMW 335i
32.... OVERVIEW OF STEERING WHEEL/CASING COMPONENTS
Fig. 4: Overview Components Of Steering Wheel/Casing Components And Assembly

32 00... CHASSIS/WHEEL ALIGNMENT CHECK PROCEDURE
CHASSIS/WHEEL ALIGNMENT CHECK PROCEDURE CHART

Check adherence to test
conditions
?
Position vehicle on measuring
stand
?
Measure vehicle ride height OK --> Carry out chassis/wheel
alignment check with ride-height
measurement without load
Read off setpoint value in KDS
Tolerance -20 / +40 mm per wheel
2007 BMW 335i
permissible
Difference between left / right
max. 10 mm permissible
Not OK / no data
I
V
Move vehicle into normal
position
Introduce load and measure ride
heights
Read off setpoint value in KDS Not OK
Tolerance ± 10 mm per wheel -->
permissible
OK Check suspension for damage,
I repair if necessary
V
Move vehicle into design position <-- Not OK
Add/distribute weights and
measure ride heights
Read off setpoint value in KDS
Tolerance ± 2 mm per wheel
permissible
?
Carry out KDS chassis/wheel
alignment check with load up to
design position
32 00... GENERAL CHASSIS AND SUSPENSION DEFINITIONS

2007 BMW 335i
Fig. 5: General Chassis And Suspension Definitions Diagram

32 00... GENERAL INFORMATION AND DEFINITIONS
Toe angle difference
a Toe angle difference
D Center point of operating circle
The toe angle difference is the angle adjustment of the inner cornering wheel relative to the outer cornering
wheel when negotiating a curve. Steering is designed in such a way that angular position of wheels changes as
steering lock progresses.
A correctly adjusted toe angle difference produces equal values for left and right lock with consideration of
factory tolerances.
2007 BMW 335i
Toe angle difference provides information on corresponding operation of steering trapezoid for left or right
steering lock from center position.
Fig. 6: Toe Angle

Camber
Inclination of the wheel from the perpendicular.
Fig. 7: Camber Inclination

Toe
Reduction in distance of front of front wheels to rear of front wheels. The toe-in prevents the wheels from
moving apart during driving and thus:
 the wheels from vibrating and grinding

 excessive tire wear
 excessive strain on the steering linkage and its links/joints
 heavy vehicle steering
2007 BMW 335i
Measurement is performed in "straight-ahead mode".
Fig. 8: Toe Distance Of Front Wheels To Rear Of Front Wheels

Caster
Is the inclination of the kingpin in the direction of travel viewed from the side. The line through the center point
of the spring strut support bearing and the control arm ball joint corresponds to the "kingpin".
Thanks to caster, wheels are pulled and not pushed. In a similar manner to king pin inclination, when driving in
curves or around corners, returning forces are reproduced to help return wheels to straight-ahead position.
Fig. 9: Caster Inclination Angle

Geometrical axis 1
Is the angle bisector from the total rear-wheel toe.
Front-wheel measurements are taken in reference to this axis.
Symmetrical axis 2
2007 BMW 335i
Center line running through front and rear axles.
Fig. 10: Geometrical Axis And Symmetrical Axis

Wheel offset
Angle by which one front wheel is displaced more towards front or rear than the other front wheel. The wheel
offset angle is positive when the right wheel is displaced towards the front and negative when it is displaced
towards the rear.
Fig. 11: Wheel Offset Angle

Kingpin offset/scrub radius
Is the distance from the center of the wheel contact face to the intersection point of the kingpin extension. The
line through the center point of the spring strut support bearing and the control arm ball joint corresponds to the
"kingpin".
The scrub radius is influenced by camber, kingpin angle and wheel offset of the wheel rim.
2007 BMW 335i
Fig. 12: Kingpin Offset/Scrub Radius Angle

32 00... IDENTIFICATION OF SUSPENSION WITHOUT LABEL
NOTE: If the front spring strut does not have a label for suspension identification, the
type of suspension can be identified from the part number in the BMW
Electronic Parts Catalogue.
32 00... IDENTIFYING SUSPENSION FROM LABEL ON FRONT AXLE
NOTE: The type of suspension can be identified from the label on the spring
strut/shock absorber.
Label:
1. BMW part number

2. Type of suspension
 BA = Standard suspension (basic)
 SP = Sport suspension or rough road package
 60BAX =E60, E61 AWD
 MSP = M Sport suspension
 CHL = China Long
 Option SA 815 = rough road package

2007 BMW 335i
Fig. 13: Suspension Label

In the case of "SP" identification, there is a further distinction between:
 Sport suspension without spacer ring (A)

 Rough road package with spacer ring (A) above the support bearing
Fig. 14: Spacer Ring

Facts:
In the event of accidents or driving conditions similar to accidents, shock-like loads can cause different types of
damage to steering gears. When a steering gear is externally undamaged, it is sometimes only possible to
identify damage with great difficulty and with great effort. However, damage of this nature poses an
unacceptable risk to the vehicle because it can result in failure of the steering system.
Because of the disproportionate amount of effort involved, it is generally not sensible to check thoroughly all
2007 BMW 335i
the individual components of the steering gear and as an alternative it is necessary to take into account other
components which can be checked more easily.
Procedure:
The steering gear must be replaced if one or more of the following points apply:
A. Visible or noticeable damage to the steering gear

 Version with electric steering gear (EPS): Examine in particular the control unit with all plug
connections for damage and hairline cracks.
B. Unacceptable torque increase and jamming when the steering gear is turned from lock to lock (without
hydraulic assistance)
C. Permissible tolerances exceeded during axle/wheel alignment check (if necessary, include alignment
record with invoice / report)
D. Fire damage
E. Damage, permanent deformation or fractures to:
 Wheel rims in the event of a negative result from the wheel/axle alignment check
 Spring struts, steering knuckles, wheel carriers
 Control arms
 Compression or tension struts or stabilizer bars with this function
 Body-side screwing/bolting points for wheel guide/control components
 Front axle carrier
 Pitman arms
 Tie rods
 Steering gear fixtures
 Steering column
This guideline is binding for all accident repairs to BMW and MINI vehicles.
NOTE: If the steering gear replacement work which is required for safety reasons is
refused by the customer or an insurance company for cost reasons, a
memorandum to that effect must be drawn up and countersigned by the party
bearing the costs of the accident repair.
IMPORTANT: The vehicle's type approval will be invalidated whenever the function of any of
its safety components is compromised!
32 00... MOVING VEHICLE INTO DESIGN POSITION

 Version with air spring system:
2007 BMW 335i
 Remove ignition key

 Pull fuse for air supply unit control unit
 Add/distribute weights in area of spring struts until the vehicle ride height is within the tolerance (refer to
Technical Data ).
Measure ride-level height of vehicle
32 00... MOVING VEHICLE INTO NORMAL POSITION
 Check compliance with test conditions, bring vehicle to a stop if necessary.

 Version with air spring system: Carry out ride-height-calibration
 Check vehicle interior and luggage compartment (incl. luggage compartment recess) for load, unload
vehicle if necessary
 Introduce DIN load (refer to Technical Data ) into vehicle
 Determine vehicle ride height
NOTE: If the vehicle ride height is not inside the tolerance (refer to Technical
Data ), the vehicle must be repaired (coil spring/leakage).
32 00... PERFORMING RIM RUNOUT COMPENSATION
NOTE: Rim runout compensation involves electronically recording the lateral runout of
the rim and the possible clamping error of the quick-clamping unit for one
wheel rotation and compensating the toe and camber for
measurement/alignment.
Raise body.
Perform rim runout compensation in accordance with equipment manufacturer's instructions.
Compress/deflect car.
00..... RAISING VEHICLE WITH TROLLEY JACK (COUPE)

contact points.
necessary.
2007 BMW 335i
Fig. 15: Identifying Trolley Jack

IMPORTANT: All-wheel drive vehicles may only be raised with the stiffening plate mounted
on the front axle (1)!
Raising directly on the front axle support without stiffening plate is not
permissible!
points!
1. Car jacking point

3. Rear axle final drive
NOTE: It is not permitted to raise the vehicle at the rear differential cover!
2007 BMW 335i
Fig. 16: Identifying Vehicle Jacking Point

1. Jacking point on front axle support (AWD)
Fig. 17: Identifying Car Jacking Point On Front Axle Carrier

Risk of damage!
Jacking point (1) must be present!
Align the rubber plate on the trolley jack to the jacking point (1) in such a way that there is no contact to
adjacent components and that they are therefore not damaged.
2007 BMW 335i

00..... RAISING VEHICLE WITH TROLLEY JACK (CONVERTIBLE)

contact points.
necessary.
Fig. 19: Identifying Trolley Jack

2007 BMW 335i
IMPORTANT: All-wheel drive vehicles may only be raised with the stiffening plate mounted
on the front axle (1)!
Raising directly on the front axle support without stiffening plate is not
permissible!
points!
1. Car jacking point

3. Rear axle final drive
NOTE: It is not permitted to raise the vehicle at the rear differential cover!
4. Bolting point for rear axle trailing links
Fig. 20: Identifying Jacking Points

Risk of damage!
Jacking point (1) must be present!
Align the rubber plate on the trolley jack to the jacking point (1) in such a way that there is no contact to
adjacent components and that they are therefore not damaged.
2007 BMW 335i

32 00... TEACHING IN CENTER POSITION FOR POWER STEERING (ACTIVE FRONT

STEERING) (FROM 03/2007)
NOTE: Carry out the following procedure after disconnecting the battery or
disconnecting electrical plug connections on the steering column switch
cluster.
Turn on ignition, start engine if necessary.
Turn steering wheel twice in both directions to full lock.
IMPORTANT: If the indicator lamp does not go out after the ignition is turned on again, an
adjustment of the active front steering must be carried out.
Fig. 22: Ignition Indicator Lamp

32 00... TEST CONDITIONS FOR CHASSIS/WHEEL ALIGNMENT CHECK
Observe the following test conditions prior to the chassis/wheel alignment check:
2007 BMW 335i
1. Only BMW approved wheel and tire combinations are installed on the vehicle.
2. Correct tread depth. The tread depth for each axle may differ from left to right by max. 1-2 mm.
3. Correct tire pressure (see label on vehicle).
4. All chassis and suspension components must be technically OK.
5. Condition of suspension and shock absorbers OK: Visually inspect for breakage, etc.
6. Vehicles with self-levelling suspension: Pull fuse of air supply system so that there is no controlling down
or up.
32 00... TROUBLESHOOTING AFTER CHASSIS/WHEEL ALIGNMENT CHECK
Substandard roadholding, atypical noises, tires worn on one side and toe-in/camber values which deviate from
the nominal value are all indicators of damage to the suspension caused by road traffic accidents or similar
impacts.
You must also follow the rules and guidelines for accident-related repairs to the steering gear.
Procedure:
 Ride-height problems:
I. Check load , correct if necessary (e.g. luggage compartment)
II. Check coil springs for damage/correct seating , replace if necessary
 Setting problems:
I. Tighten all suspension screw/bolt connections to specified torque
II. Check all suspension components for deformation/damage or retrofits, replace if necessary
CAUTION: When replacing deformed or damaged suspension components,

also check the adjoining components for damage and replace if
necessary (comply with repair instructions).
NOTE: If after chassis/suspension components have been replaced adjustment of

camber/track alignment is not possible, the vehicle must be placed on the body
straightening bench.
32 00 150 KDS CHASSIS/WHEEL ALIGNMENT CHECK WITH LOAD UP TO DESIGN POSITION
IMPORTANT: Carry out wheel alignment with DIN load only:
 If the technical prerequisites for alignment with ride height input are not
fulfilled
 if the vehicle in question is a damaged vehicle
NOTE:  Read and comply with General information and definitions.

2007 BMW 335i
 Read and comply with General chassis definition.

 Check compliance with test conditions, repair vehicle if necessary.
 If necessary, prepare vehicle hoist.

 Drive vehicle onto vehicle hoist.
NOTE: The front and rear wheels must be positioned centrally on the rotary and
sliding plates.
NOTE: Rotary plates may deviate from the depiction depending on the
manufacturer!
Fig. 23: Identifying Rotary And Sliding Plates

NOTE: Vehicles with active steering:
Start up active steering prior to wheel alignment!
Attach pickup/ride-height marks to vehicle (observe regulation of the different device manufacturers).
IMPORTANT: Use quick-clamping holders with poly control arm bushings only.
Due to excessive measuring inaccuracy, other quick-clamping units are not

permitted!
Illustration of KDS II pickup

2007 BMW 335i
Fig. 24: Identifying Poly Control Arm Bushings

 Enter customer and vehicle data

 Identify chassis version and select vehicle
 Enter tire inflation pressure and tread depth
 Move vehicle into design position
 Install brake tensioner.
Fig. 25: Locating Brake Tensioner


2007 BMW 335i
In order to avoid damaging the front side panel during the "Max. steering
angle" drive-in routine, make sure the pickups are removed from the quick-
clamping holders/quick-clamping units during output and input alignment. In
the process do not detach the connecting cable from the pickups or the rotary
plates.
NOTE: After the drive-in routine, reconnect the pickups to the quick-clamping
holders/quick-clamping units, align using the bubble levels and secure in place.
 Remove locking pins from both rotary and sliding plates.

 Perform input measurement in accordance with equipment manufacturer's instructions.
 If necessary, adjust front axle and rear axle
 Perform output measurement in accordance with equipment manufacturer's instructions.
 Save and print out test record.
 Insert locking pins into both rotary and sliding plates
 Remove wheel alignment system
 If necessary, carry out alignment of ACC sensor
IMPORTANT: Only on vehicles with Active Cruise Control:
Because the driving axis is the reference for ACC alignment, it is necessary
after an alignment of the rear axle, which alters the driving axis, to check the
alignment of the ACC sensor as well!
It is not necessary to check the ACC sensor after only one adjustment of the
front axle!
Only in event of customer complaint (e.g. poor driving performance):
IMPORTANT: Do not remove screws/bolts (front axle support to engine support or body)!
Slacken all screws/bolts (front axle support to engine support or body) and then retighten to specified torque.
Refer to Lowering front axle support .
32 00 155 KDS CHASSIS/WHEEL ALIGNMENT CHECK WITH RIDE-HEIGHT MEASUREMENT

WITHOUT LOAD
IMPORTANT: Only perform wheel alignment without vehicle load:
 if the technical prerequisites for an alignment check with ride-height input

are not fulfilled
 if the vehicle in question is a damaged vehicle
2007 BMW 335i
NOTE:  Read and comply with General information and definitions.

 Read and comply with General chassis definition.
 Check compliance with test conditions, repair vehicle if necessary.
 If necessary, prepare vehicle hoist.

 Drive vehicle onto vehicle hoist.
NOTE: The front and rear wheels must be positioned centrally on the rotary and
sliding plates.
NOTE: Rotary plates may deviate from the depiction depending on the
manufacturer!
Fig. 26: Identifying Rotary And Sliding Plates

NOTE: Vehicles with active steering:
Start up active steering prior to wheel alignment!
On vehicles with rear axle slip angle control:
Service function "Moving HSR actuator to center position" is included in active

steering start-up.
Attach pickup/ride-height marks to vehicle (observe regulation of the different device manufacturers).
IMPORTANT: Use only quick connectors with poly control pins (1).
Due to excessive measuring inaccuracy, other quick-clamping units are not

permitted!
2007 BMW 335i
Illustration of KDS II pickup
Fig. 27: Identifying Poly Control Arm Bushings

 If necessary, switch on chassis alignment system.

 Enter customer and vehicle data
 Identify chassis version and select vehicle
 Enter tire inflation pressure and tread depth
 Measure vehicle ride height with tape measure (only Beissbarth KDS II wheel alignment equipment)
If the ride height is outside the tolerance range (+40/-20 mm), load or unload vehicle accordingly to
adjust the vehicle in this ride-height window
 Install brake tensioner.

2007 BMW 335i
Fig. 28: Locating Brake Tensioner

In order to avoid damaging the front side panel during the "Max. steering
angle" drive-in routine, make sure the pickups are removed from the quick-
clamping holders/quick-clamping units during output and input alignment. In
the process do not detach the connecting cable from the pickups or the rotary
plates.
NOTE: After the drive-in routine, reconnect the pickups to the quick-clamping
holders/quick-clamping units, align using the bubble levels and secure in place.
 Remove locking pins from both rotary and sliding plates.

 Perform input measurement in accordance with equipment manufacturer's instructions.
 If necessary, adjust front axle and rear axle
 Perform output measurement in accordance with equipment manufacturer's instructions.
 Save and print out test record.
 Insert locking pins into both rotary and sliding plates
 Remove wheel alignment system
 If necessary, carry out alignment of ACC sensor
Only in event of customer complaint (e.g. poor driving performance):
IMPORTANT: Do not remove screws/bolts (front axle support to engine support or body)!
Slacken all screws/bolts (front axle support to engine support or body) and then retighten to specified torque.
2007 BMW 335i
Refer to Lowering front axle support .
IMPORTANT: Only on vehicles with Active Cruise Control:
Because the driving axis is the reference for ACC alignment, it is necessary
after an alignment of the rear axle, which alters the driving axis, to check the
alignment of the ACC sensor as well!
It is not necessary to check the ACC sensor after only one adjustment of the
front axle!
32 00 610 ADJUSTING TOE-IN AND CAMBER ON FRONT AXLE
 32 3 140
 32 3 146
 32 3 147
IMPORTANT: Changes in axle geometry caused by accidents must under no circumstances

be rectified by camber adjustment!
NOTE: Camber and toe-in influence each other. Adjust the toe-in first in order to
simplify the adjustment procedure.
The centering pin may only be driven or twisted out if the camber is outside the
specified tolerance after toe adjustment.
Version with active front steering:
 Align steering wheel

 Set cumulative steering angle by means of the service function to "zero". Carry out initial
operation/adjustment for active front steering.
 If necessary, secure with steering wheel arrester
Version without active front steering:
Move steering into straight-ahead position by means of markings on cap (1) and steering gear (2).
Align steering wheel and secure with steering wheel arrester.

2007 BMW 335i
Fig. 29: Cap, Alignment Markings And Steering Gear

Adjust toe-in:
Clean thread on tie rod.
Loosen screw (2).
Turn tie rod (3) and if necessary grip tie rod end (1) to adjust toe-in to setpoint value.
Tighten screw (2).
For tightening torque refer to 32 21 2AZ in 32 21 STEERING ARMS, TIE RODS, STEERING DAMPER .
If necessary, correct installation position of gaiter.
Fig. 30: Tie Rod End, Screws And Tie Rod

2007 BMW 335i
Adjusting camber:
Remove tension strut for spring strut dome.
Remove protective cap.
Twist/drive out centering pin (1).
Clean wheel arch from below in area of support bearing with compressed air.
Slacken nut (2).
Fig. 31: Centering Pin And Nut

Insert special tool 32 3 140 into opening in wheel arch.
NOTE: The spindle 32 3 146 must be aligned in such a way that the short end of the
guide sleeve (3) points upwards.
Screw knurled nut 32 3 147 onto stud.
Replace nuts (1) and screw on but do not tighten down fully.
Turn nut (2) of special tool 32 3 140 to adjust camber to setpoint value.
For tightening torque refer to 31 31 1AZ in 32 31 STEERING COLUMN .

2007 BMW 335i
Fig. 32: Special Tools (32 3 147), (32 3 140), Nuts And Guide Sleeve
Replace nut (1) and tighten down.
For tightening torque refer to 31 31 1AZ in 32 31 STEERING COLUMN .
Fig. 33: Nut

After installation:
 Check directional stability of car; if necessary, repeat toe-in adjustment
32 00 620 ADJUSTING REAR AXLE
NOTE: A camber change always means a toe change as well. The camber must
therefore be adjusted first.
Adjusting camber:
2007 BMW 335i
Replace nut (2) and tighten to 5 Nm.
Turn eccentric bolt (1) to adjust camber to setpoint value.
Tighten nut (2).
Fig. 34: Nut, Eccentric Bolt And Adjustment Directions

Adjusting toe:
Replace nut (2) and tighten to 5 Nm.
Turn eccentric bolt (1) to adjust toe to specified value.
Tighten nut (2).

2007 BMW 335i
Fig. 35: Nut, Eccentric Bolt And Adjustment Directions

32 10 005 ADJUSTMENT FOR ACTIVE FRONT STEERING
NOTE: Adjustment of the active front steering must be carried out:
 after adjustment work on the front axle/steering

 after all mechanical work on the steering system
 after the battery has been disconnected or electrical plug connections on
the steering column switch cluster have been disconnected
 after replacement/programming or coding of the following components:
 Steering column switch cluster
 DSC control unit
 Active front steering control unit
 ARS control unit
Connect vehicle to BMW diagnosis system.
Carry out adjustment for active front steering.
61 31 996 CARRYING OUT STEERING ANGLE SENSOR ADJUSTMENT
See STEERING ANGLE SENSOR ADJUSTMENT .
31 00... FRONT AXLE + STEERING: WHEEL/CHASSIS ALIGNMENT CHECK AFTER SPECIFIED

WORK

2007 BMW 335i


2. Steering gear
4. Control arm
6. Swivel bearing
7. Tie rod end
8. Tie rod
See ALIGNMENT CHECK WITH VEHICLE LOAD UP TO DESIGN POSITION or ALIGNMENT

CHECK WITH RIDE HEIGHT MEASUREMENT WITHOUT VEHICLE LOAD
Fig. 36: Identifying Front Axle Steering Wheel Components

2007 BMW 335i
31 00... FRONT AXLE + STEERING (AWD): WHEEL/CHASSIS ALIGNMENT CHECK AFTER

SPECIFIED WORK

 Compression strut to front axle carrier

2. Steering gear
4. Control arm
6. Swivel bearing
7. Compression strut or compression strut rubber mount
8. Tie rod end
9. Tie rod

2007 BMW 335i
Fig. 37: Identifying Front Axle And Steering (AWD) Components

33 00... REAR AXLE: WHEEL/CHASSIS ALIGNMENT CHECK AFTER SPECIFIED WORK

 Camber arm to rear axle carrier/wheel carrier
 Trailing arm to rear axle carrier/wheel carrier
 Guide arm to rear axle carrier
 Toe arm to rear axle carrier/wheel carrier
 Control arm to rear axle carrier

1. Rear axle carrier
2. Camber arm/rubber mount/ball joint
3. Trailing arm/rubber mount
4. Guide arm
5. Wheel carrier/rubber mount/ball joint
6. Toe arm
2007 BMW 335i
7. Control arm

Fig. 38: Identifying Rear Axle Carrier And Related Components

32 10... TEACHING IN END STOP SOFTWARE FOR ELECTRIC STEERING GEAR (EPS)
NOTE: The end stop software must be taught in:
 after the steering gear is replaced

 after programming/coding
Connect vehicle to BMW diagnosis system.
Select and perform end stop under Service functions.
MECHANICAL STEERING GENERAL

2007 BMW 335i
See INFORMATION ON REPLACING STEERING GEAR AFTER ACCIDENT DAMAGE.
32 11... NOTES ON CHECKING STEERING BACKLASH ON VEHICLES WITH RACK-AND-

PINION STEERING (WITH FRONT AXLE RAISED)
NOTE: When the front axle is raised, the applied force is distributed via the tie rod into
horizontal and vertical forces. If there is now no electric or hydraulic assistance,
the forces created cause the thrust member (1) to be unloaded against the
spring (2). The play created in this way is incorrectly referred to as steering
backlash.
3 = Rack
Fig. 39: Identifying Thrust Member, Spring And Rack

IMPORTANT: Target status: steering must be free from play in all the mechanical
components (except for steering gear and tie rod)!
NOTE: For checking purposes, the steering gear must be pressurized by means of
electric or hydraulic assistance.
 Hydraulic steering assistance: Start engine

 Electro-hydraulic steering assistance: Switch ignition on
 Electric steering assistance: Turn on ignition and start engine
32 11... REPLACING GAITER FOR ELECTRIC STEERING GEAR (EPS) ON LEFT OR RIGHT
Spindle side:
IMPORTANT: The steering gear must be replaced If the corrosion on the spindle running
surface has advanced to such an extent that the steering is acoustically
conspicuous under load!
2007 BMW 335i
Adhere to the utmost cleanliness.
Do not regrease the spindle running surface. Sufficient special grease was
used during assembly for lifetime filling.
Fig. 40: Electric Steering Gear Spindle Side

Rack side:
IMPORTANT: The steering gear must be replaced if the polished surface of the rack is
damaged (e.g. by corrosion)!
Clean rack and check surface for damage (e.g. by corrosion).
Grease rack (refer to BMW Service Operating Fluids ).
Fig. 41: Electric Steering Gear Back Side

2007 BMW 335i
 Remove front assembly underside protection
Clean tie rod.
Release band clamp (1).
Mark screw-in depth of tie rod (2) or count thread turns.
Unscrew bolt (3).
Twist tie rod (2) out of tie rod end (4).
Installation:
Replace microencapsulated screw.
Fig. 42: Clamp, Tie Rod, Bolt And Tie Rod End
Release ear clamp (1).
Detach gaiter (2) from tie rod (3).
Installation:
Read and follow notes/information on spindle and rack sides at the start of the document.
Clean tie rod and apply grease to taper. This ensures that the gaiter is not rotated when the tie rod is rotated.
2007 BMW 335i
Fig. 43: Ear Clamp, Gaiter, Tie Rod And Removal Direction
Release water drain valve (1) (20 A/F) and replace.
Installation:
Fit O-ring (2).
For tightening torque refer to 32 00 3AZ in 32 00 STEERING .
Fig. 44: Water Drain Valve And O-Ring

After installation:

32 11 100 REPLACING GAITER FOR STEERING BOX ON LEFT OR RIGHT

2007 BMW 335i
IMPORTANT: The power steering gear must be replaced if the polished surface of the rack is
Clean tie rod.
Mark screw-in depth of tie rod (2) or count thread turns.
Release screw (3).
Twist tie rod (2) out of tie rod end (4).
Installation:
Fig. 45: Clamp, Tie Rod, Screws, Bolt And Tie Rod End
Detach gaiter (2) from tie rod (3).
Installation:

2007 BMW 335i
Grease rack (refer to BMW Service Operating Fluids ).
Clean tie rod and apply grease to taper. This ensures that the gaiter is not rotated when the tie rod is rotated.
Fig. 46: Ear Clamp, Gaiter, Tie Rod And Removal Direction
After installation:

 Carry out steering angle sensor adjustment or adjustment for active front steering
32 11 100 REPLACING GAITER FOR STEERING BOX ON LEFT OR RIGHT (AWD)
IMPORTANT: The hydraulic steering gear must be replaced if the polished surface of the rack
is damaged (e.g. by corrosion)!
 If necessary, remove diesel enclosure
Clean track rod.
Mark screw-in depth of track rod (2) or count thread turns.
Release screw (3).
Twist track rod (2) out of track rod end (4).
Installation note:
2007 BMW 335i
Tightening torque, see 2AZ in 32 21 STEERING ARMS, TIE RODS, STEERING DAMPER
Fig. 47: Identifying Band Clamp And Track Rod With Screws
NOTE: E9x only:
Heat shield is only fitted on the right side.
Release screws (1) and remove heat shield (2).
Tightening torque, see 4AZ in 32 21 STEERING ARMS, TIE RODS, STEERING DAMPER
2007 BMW 335i
Fig. 48: Identifying Heat Shield With Screws

Detach gaiter (2) from track rod.
Installation note:
Grease rack (refer to BMW Service Operating Fluids). See STEERING AND WHEEL ALIGNMENT -
OPERATING FLUIDS
Clean track rod and apply grease to taper.

2007 BMW 335i
Fig. 49: Removing Gaiter From Track Rod

NOTE: This ensures that the gaiter is not rotated when the track rod is rotated.
After installation
 Perform chassis/wheel alignment check

STEERING GEAR WITH SERVO UNIT

See INFORMATION ON REPLACING STEERING GEAR AFTER ACCIDENT DAMAGE.
32 13 006 BLEEDING POWER STEERING UNIT
system.
Using contaminated equipment to add fluid may introduce dirt particles into the
fluid reservoir and significantly reduce the service life of the power steering
system. Do not use any filler funnels or similar!
2007 BMW 335i
The fill level may only be checked or adjusted when the engine is stopped! The
fluid temperature should be approx. 20 °C here.
Ensure that the cap is fully screwed in prior to the fill level check.
NOTE: To avoid mix-ups when filling with hydraulic fluid, mark the fluid reservoirs or
their caps with identification marks.
ATF Automatic transmission fluid
CHF Pentosin CHF11S
Fig. 50: Reservoirs Caps

1. Thoroughly clean fluid reservoir and its immediate surroundings

2. Check and correct fill level
NOTE: The fill level can come to rest above the "MAX" mark when the engine is at
normal operating temperature. This is dictated by the design in that the
marking on the dipstick is referred to a fluid temperature of 20 °C. With the
engine at normal operating temperature (approx. 50-60 °C fluid
temperature) adjust a fill height 10 mm above the "MAX" mark. Do not
under any circumstances draw off the fluid to the "MAX" mark when the
engine is at normal operating temperature.
Hydraulic fluid: BMW Service Operating Fluids
3. Start engine
4. Turn steering wheel left and right twice in each case up to full lock; if necessary, top up hydraulic fluid
(e.g. if hydraulic system is completely drained)
5. Move steering wheel to straight-ahead position and turn off engine
2007 BMW 335i
6. Check and correct fill level with engine stopped

7. Check hydraulic system for leaks
32 13 060 REMOVING AND INSTALLING/REPLACING HYDRAULIC STEERING GEAR
system.
Seal off pipe connections with plugs.
 Draw off and dispose of hydraulic fluid from fluid reservoir

 Remove both tie rod ends from swivel bearing
 Replacement only: Remove both tie rod ends from tie rod
 Remove lower steering shaft from power steering gear
If necessary, remove heat shield from power steering gear.
Release banjo bolts (1, 4).
Disconnect pressure line (2) and return line (3) from power steering gear.
If necessary, remove hydraulic lines with bracket from power steering gear.
Installation:
Replace all sealing rings.
Make sure hydraulic lines are laid without tension and with sufficient spacing to adjoining components.
For tightening torque refer to 32 41 9AZ (pressure line) in 32 41 PUMP AND OIL SUPPLY .
For tightening torque refer to 32 41 10AZ (return line) in 32 41 PUMP AND OIL SUPPLY .
2007 BMW 335i
Fig. 51: Banjo Bolts, Pressure Line And Return Line

Release nuts and remove screws (1) towards bottom.
Remove power steering gear (2) towards front.
Installation:
Replace screws and nuts.
Fig. 52: Screws And Power Steering Gear

After installation:
 Fill and bleed hydraulic system

2007 BMW 335i

32 13 060 REMOVING AND INSTALLING/REPLACING HYDRAULIC STEERING GEAR (AWD)

N51 ENGINE or N52 ENGINE .
system.
Seal off hydraulic lines with plugs.

 Secure engine in installation position. See N51 ENGINE or N52 ENGINE .
 Remove TIE ROD END ON BOTH SIDES FROM SWIVEL BEARING
 Replacement only:
Remove TIE ROD END AT BOTH ENDS OF TIE ROD
 Lower FRONT AXLE SUPPORT
Remove cooler return line from front axle carrier.
Installation:
Tightening torque, see 9AZ (pressure line) in 32 41 PUMP AND OIL SUPPLY .
Tightening torque, see 10AZ (return line) in 32 41 PUMP AND OIL SUPPLY .
2007 BMW 335i
Fig. 53: Identifying Steering Gear Pressure Line, Return Line And Banjo Bolts
M57T2:
Disengage vacuum line for engine mount on front axle carrier.
Lower front axle carrier further.
NOTE: Heat shield is only fitted on the right side.
If necessary, release screws (1) and remove heat shield (2).
Tightening torque: see 4AZ in 32 21 STEERING ARMS, TIE RODS, STEERING DAMPER .
Fig. 54: Identifying Heat Shield With Screws

2007 BMW 335i
Remove power steering gear (2) to one side.
Installation:
Replace screws and self-locking nuts.
Tightening torque: see 1AZ in 32 00 STEERING .
Fig. 55: Identifying Power Steering Gear With Screws

After installation
 FILL AND BLEED hydraulic system

 Perform chassis alignment check. See ALIGNMENT CHECK WITH VEHICLE LOAD UP TO
DESIGN POSITION or ALIGNMENT CHECK WITH RIDE HEIGHT MEASUREMENT
WITHOUT VEHICLE LOAD
 Carry out STEERING ANGLE SENSOR ADJUSTMENT
32 13 065 REMOVING AND INSTALLING (REPLACING) HYDRO-STEERING GEAR FOR ACTIVE

STEERING
system.
Seal off pipe connections with plugs.

2007 BMW 335i
Recycling:
Catch and dispose of hydraulic fluid in a suitable container.

 Remove diesel enclosure on driver's side
 Replacement only: Remove both tie rod ends from tie rod
 Disconnect plug connection from power steering pump and expose connecting cable up to power steering
gear
Installation:
For tightening torque refer to 32 41 9AZ (pressure line) in 32 41 PUMP AND OIL SUPPLY .
For tightening torque refer to 32 41 10AZ (return line) in 32 41 PUMP AND OIL SUPPLY .
2007 BMW 335i
Fig. 56: Banjo Bolts, Pressure Line And Return Line

Release screws (1) and remove brackets.
Release screws (2) and tie up pressure line.
For tightening torque refer to 32 41 11AZ in 32 41 PUMP AND OIL SUPPLY .
Fig. 57: Screws

Build date up to 03/2007: Disconnect plug connection (2) on cumulative steering angle sensor.
2007 BMW 335i

Tie up power steering gear to prevent it from falling down when

disconnecting plug connections.
Do not expose connecting cables to tensile load.
Move power steering gear forwards and tie up.
Installation:

2007 BMW 335i
Fig. 59: Screws

Disconnect plug connections (1) and remove steering gear.

After installation:

 Carry out adjustment for active front steering
32 13 070 REMOVING AND INSTALLING (REPLACING) ELECTRIC STEERING GEAR (EPS)
IMPORTANT: Steering gear:

2007 BMW 335i
Check connection of steering gear for corrosion, clean contacts if necessary.

The steering gear must be replaced if the corrosion is too far advanced.
Connecting cable:
In the event of moisture/corrosion inside the two plug connections, check the
insulation of the connecting cable. If the insulation reveals any
noticeable/striking features, it will be necessary to replace the part. Otherwise
it will be sufficient to replace the contacts or plug housing.
NOTE: In a warranty case you must always provide a fault memory printout, even
where there is no fault memory entry, with the defective part.
NOTE: High-current-carrying lead laid with permanent positive connection (80 A

fuse protection).
 Remove front underbody protection

 Replacement: Remove both tie rod ends from steering gear
Installation:
Check plug connections for moisture and corrosion. To do so, read and follow notes/information at the start of
the document.
Plug connections must audibly snap into place.
Make sure connecting lead is correctly laid.

2007 BMW 335i
Fig. 61: Cable Tie And Plug Connections

Remove steering gear (2) towards front.
Installation:
Fig. 62: Screws And Steering Gear

After installation:
 Replacement: Carry out programming/coding

 Teach in end stop software
2007 BMW 335i

32 13 650 REMOVING AND INSTALLING/REPLACING EH CONVERTER FOR SERVOTRONIC
system.
Release screws (2).
Remove EH converter (3).
Installation:
Clean side return orifice with compressed air. Align EH converter (3) to opening in power steering gear, press
by hand into power steering gear up to stop, insert screws (2) and tighten down.
Tightening torque: see 4AZ in 32 00 STEERING .
Fig. 63: Removing EH Converter For Servotronic

After installation:
STEERING ARM, TIE RODS, STEERING DAMPER

32 21 151 REPLACING LEFT OR RIGHT TIE ROD END
2007 BMW 335i
NOTE: If the tie rod end to tie rod screw/bolt connection is released, it is necessary
after reinstallation to carry out a wheel/chassis alignment check.
 Remove front wheel
IMPORTANT: Do not release tie rod end from swivel bearing with impact tool.
Rubber gaiter of tie rod end must not be damaged!
Release nut (1); if necessary, grip at Torx socket.
Remove tie rod end (2) from swivel bearing.
Installation:
Keep tie rod end to swivel bearing connection clean and free from oil and grease.
Fig. 64: Nut And Tie Rod End

Determine measurement (A) to simplify following adjustment of front axle.
Release screw (1).
Screw off tie rod end; if necessary, grip tie rod with open-end wrench.
Installation:
2007 BMW 335i
Check gaiter for damage, replace if necessary.
Screw in tie rod end to measurement (A).
Fig. 65: Measurement And Screw

After installation:

32 21 151 REPLACING LEFT OR RIGHT TIE ROD END (AWD)
NOTE: If the tie rod end to tie rod screw/bolt connection is released, it is necessary
after reinstallation to carry out a wheel/chassis alignment check.
 Remove front wheel
IMPORTANT: Do not release tie rod end from swivel bearing with impact tool.
Rubber gaiter of tie rod end must not be damaged!
Do not pull stainless steel ring off journal.
Slacken nut (1); if necessary, grip at Torx socket.
Press tie rod end (2) with special tool 31 2 300 off swivel bearing.
Unscrew nut (1).

2007 BMW 335i
Installation:
Keep tie rod end (2) to swivel bearing connection clean and free from oil and grease.
Fig. 66: Pressing Tie Rod End Using Special Tool 31 2 300
Determine measurement (A) to simplify following adjustment of front axle.
Release bolt (1).
Screw off tie rod end; if necessary, grip tie rod with open-end wrench.
Installation:
Check GAITER for damage, replace if necessary.
Screw tie rod end onto tie rod to measurement (A).
2007 BMW 335i
Fig. 67: Identifying Tie Rod With Mounting Screw

After installation
 Perform chassis alignment check. See ALIGNMENT CHECK WITH VEHICLE LOAD UP TO
DESIGN POSITION or ALIGNMENT CHECK WITH RIDE HEIGHT MEASUREMENT
WITHOUT VEHICLE LOAD
32 21 231 REPLACING LEFT OR RIGHT TIE ROD
IMPORTANT: The steering gear must be replaced if the polished surface of the rack is
 Remove tie rod end from swivel bearing

 Remove gaiter from steering gear and slide back
IMPORTANT: To avoid damage to rack and to suspension mounting, move rack in as far as
possible.
Release joint (1) with standard tool (38 WAF) from steering gear rack.
Installation:
Clean rack.
Check surface of rack for damage (e.g. corrosion).

2007 BMW 335i
Power steering gear only: Grease rack (refer to BMW Service Operating Fluids ).
Fig. 68: Joint

On replacement, assemble new part with gaiter:
 Determine measurement (A) to simplify following adjustment of front axle.
Installation:
Slacken clamping screw (1) and screw off tie rod end.
Push clamp and gaiter onto tie rod.
Screw in tie rod end to measurement (A).
Fig. 69: Measurement And Screw

2007 BMW 335i
After installation:

STEERING COLUMN
32 31 003 REMOVING AND INSTALLING/REPLACING UPPER SECTION OF STEERING
COLUMN TRIM
 00 9 323

After installation:
 Read out fault memory and delete entries
Move steering column in "bottom" and "extended" position.
Unclip steering column trim (1) at side with special tool 00 9 323.
Fig. 70: Special Tool (00 9 323) And Steering Column Trim
2007 BMW 335i
Tilt steering column trim (1) towards front.
Unclip steering column gap cover (2) from steering column trim.
Installation:
Tilt steering column trim towards rear, align by way of locks to lower section (of steering column trim) and
press down.
Fig. 71: Steering Column Trim, Locks And Steering Column Gap Cover
Replacement:
E93: Remove hands-free microphone from steering column trim.
32 31 020 REMOVING AND INSTALLING / REPLACING LOWER SECTION OF STEERING

COLUMN TRIM
 Remove upper section of steering column trim

 Move steering column into "top" and "extended" position and do not secure with adjusting lever
Press detent lugs outwards a little and unclip steering column trim downwards.
Installation:
Align steering column trim by means of detent lugs to steering column and press up as far as it will go.
Press steering column trim on both sides together a little and then press upwards completely until detent lugs
snap into place.
2007 BMW 335i
Check installation position, correct if necessary.
Fig. 72: Detent Lugs And Steering Column Trim Removal Directions
32 31 070 REMOVING AND INSTALLING/REPLACING LOWER SECTION OF STEERING SHAFT
IMPORTANT: If the lower section of the steering shaft is separated from the steering
gear/steering column, the steering-column switch cluster may be damaged
when the steering wheel is turned.
 Move steering column adjuster to "top" and "extended" position

 Secure upper section of steering shaft in footwell (can be pushed into steering column)
 N51, N52, N53: Remove INTAKE FILTER HOUSING with air intake hose to intake manifold/system
Release clamping screw (1) on steering shaft upper section (2).
Installation:
Clean thread to remove all remnants of screw securing adhesive.
Replace clamping screw.
Clamping screw must rest in groove of steering column.
No kinking permitted!
Tightening torque: see 1AZ in 32 31 STEERING COLUMN .

2007 BMW 335i
Fig. 73: Identifying Clamping Screw On Steering Shaft Upper Section

Release clamping screw (1) on steering shaft lower section (2).
Move steering wheel to straight-ahead position and remove ignition key.
Detach steering shaft lower section in direction of arrow from steering gear.
Detach steering shaft upper section from steering column.
Installation:
Fig. 74: Identifying Clamping Screw On Steering Shaft Lower Section


2007 BMW 335i
Clamping screw must rest in groove of steering gear.
Steering shaft can only be attached in one position on steering gear and steering column.
After installation
 Turn steering wheel in both directions to full lock. The airbag warning lamp must not light up in the
process.
 Carry out steering angle sensor adjustment for active front steering. See steering angle sensor
adjustment or adjustment for active front steering.
 Check directional stability of car.
32 31 070 REMOVING AND INSTALLING/REPLACING BOTTOM STEERING SHAFT (AWD)
IMPORTANT: If the lower section of the steering spindle is separated from the double
joint/steering column, the steering-column switch cluster may be damaged
when the steering wheel is turned.
 Remove trim panel for pedal assembly. See REMOVING AND INSTALLING/REPLACING PANEL
FOR PEDALS
 Secure upper section of steering spindle in footwell (can be pushed into steering column)
 Remove left N54charge-air duct
N51, N52, N53:
Remove intake filter housing with intake hose to intake manifold/system. See INTAKE SILENCER .
Remove vacuum line (1) from bracket.
Release nuts (2) and remove shims.
Remove oil reservoir (3) with bracket from combination bracket, pass under vacuum line (1) and place to one
side.
Installation:
Tightening torque, see 2AZ in 32 41 PUMP AND OIL SUPPLY

2007 BMW 335i
Fig. 75: Identifying Vacuum Line Of Bracket And Shims Nuts

Release clamping screw (1) on steering spindle upper section (2).
Installation:
Replace clamping screw
Clamping screw must rest in groove of steering column.
No subsequent buckling permitted!
Tightening torque, see 4AZ in 32 31 STEERING COLUMN .

2007 BMW 335i
Fig. 76: Identifying Clamping Screw On Steering Spindle Upper Section

Release clamping screw (1).
Return steering to straight-ahead drive setting and remove ignition key.
Pull steering spindle lower section (3) in direction of arrow out of double joint (4).
Detach steering spindle upper section from steering column.
Installation:
Clamping screw must rest in groove (2) of steering spindle lower section (3).
No subsequent buckling permitted!
Steering spindle can only be attached in one position on double joint and steering column.
Fig. 77: Pulling Steering Spindle Lower Section From Double Joint
After installation
2007 BMW 335i
process.
32 31 082 REMOVING AND INSTALLING/REPLACING STEERING ANGLE SENSOR
NOTE: Steering angle sensor is integrated in the steering column stalk fixture.
After installation:
 Replacement only: Carry out programming/coding

 Carry out steering angle sensor adjustment or adjustment for active front steering.
32 31 090 REMOVING AND INSTALLING/REPLACING STEERING COLUMN
WARNING: Observe the following instructions to avoid any risk of injury by the
airbag unit.
 Comply with safety regulations for handling components with gas

generators.
 Do not exert any force on the airbag unit.
 Use only specified tools for releasing the airbag unit.
WARNING: Incorrect handling may result in triggering of the airbag unit and thereby
cause serious injury.
NOTE: Vehicles manufactured up to 12/2004 have a steering column with a three-pin

plug connection for the electrical steering column locking. Vehicles
manufactured after this have a four-pin plug connection. Spare parts are offered
for both versions.

 Remove footwell heating duct
 Remove upper and lower steering column shrouds
 Remove steering column trims
 Disconnect all plug connections at mounting for switch of steering column
 Disconnect plug connection on electric steering column lock
 Remove wiring harnesses on steering column
 Slide sleeve for steering shaft on steering column upwards. This work is described under Replacing
steering spindle sleeve.
Installation note:
2007 BMW 335i
Slide sleeve into bulkhead and check installation position; correct if necessary.
Undo clamping bolt (1) on steering column (2).
Installation note:
Clean thread to remove all remnants of screw locking adhesive.
Replace clamping bolt
Clamping bolt must rest in groove of steering column.
No subsequent retorquing permitted!
Fig. 78: Identifying Clamping Screw And Steering Column

Release screws (1).
Secure steering column against falling out.
Remove steering column towards rear.
Installation:
When inserting the steering column into the sleeve, make sure the sleeve is not pressed out of the bulkhead.
2007 BMW 335i
Check installation position of sleeve, correct if necessary.
Fig. 79: Screws

Replacement:
 Modify airbag unit

 Modify steering wheel
 Modify fixture for steering column switch
After installation:
 Replacement: Lock and unlock electric steering column lock and clear fault memory in Car Access
System (CAS).
 Replacement: Turn steering wheel in both directions to the limit position. The airbag indicator lamp must
not light up in the process.
32 31 102 REPLACING STEERING SHAFT SLEEVE
 Remove lower section of steering shaft
Push steering shaft into steering column.
Pop sleeve (1) out of bulkhead and press together.

2007 BMW 335i
Fig. 80: Sleeve

Installation:
Detach pull-in lug from sleeve and lubricate gap with silicone grease.
Press sleeve together, slide onto steering column, align to opening in bulkhead and insert in bulkhead.
NOTE: To prevent the sleeve from slipping out and to avoid complaints by the
customer about noise, make sure that sealing lip (1) on engine compartment
side rests against bulkhead all round and sealing lip (2) in inside the car rests
against the damping.
Fig. 81: Sealing Lips

Installation:
2007 BMW 335i
CAUTION: Check installation location.
Marking (1) on sleeve must point to stud (2).
Fig. 82: Identifying Marking On Sleeve And Stud

After installation:
32 31 201 REPLACING UNIVERSAL JOINT FOR UPPER SECTION OF STEERING SHAFT

IMPORTANT: If the universal joint is separated from the lower section of the steering
spindle/steering column, the steering column switch cluster may be damaged
when the steering wheel is turned!
 Remove INTAKE FILTER HOUSING

 Remove LEFT or RIGHT microfilter housing lower section.
 Remove left ignition coil cover
Disconnect plug connection (1) and remove auxiliary water pump (2) towards top from body.
Set down auxiliary water pump (2) on valve cover; if necessary, remove water hoses from hose holder(s).
Installation:
2007 BMW 335i
Insert auxiliary water pump into body so that bearings slide correctly in associated mountings.
Fig. 83: Identifying Plug Connection And Auxiliary Water Pump

Release clamping screws (1).
Move steering column in "top" and "extended" position.
Detach universal joint (2) first from steering column and then from lower section of steering spindle.
Installation:
Universal joint can only be attached in one position to steering column and lower section of steering spindle.
Replace clamping screws.

2007 BMW 335i
Fig. 84: Identifying Universal Joint And Steering Column Screws

Clamping screws must rest in groove of steering column or lower section of steering spindle.
After installation
process.
 Check directional stability of car
32 31 241 REPLACING ADJUSTING LEVER FOR STEERING COLUMN
 Remove steering column
If necessary, remove cable duct from steering column.
Unclip adjusting lever.
Installation:
Align adjusting lever to steering column and attach straight to prevent the locks from being damaged.
Check locks after attachment, replace adjusting lever if necessary.

2007 BMW 335i
Fig. 85: Cable Duct

STEERING WHEEL
32 33... REPLACING COVER FOR SPORT STEERING WHEEL

 Remove airbag unit
NOTE: Sport steering wheel (4) was only removed to generated the picture.
Release screws (1).
Release cover (3) from holders (2); if necessary, disconnect associated plug connection.
Version with multifunction: remove sport steering wheel switches
Installation:
Replace damaged cover.

2007 BMW 335i
Fig. 86: Screws, Holders, Cover, Sport Steering Wheel And Removal Direction
32 33 010 REMOVING AND INSTALLING/REPLACING SPORT STEERING WHEEL
NOTE: Wheel/chassis alignment is not necessary after the steering wheel has been
removed and installed or replaced.

 Remove airbag unit
Set road wheels/steering wheel to straight-ahead position.
If necessary, disconnect plug connection (2) for steering wheel heating.
Release screw (3) and remove steering wheel (4).
Installation:
Make sure connecting lead(s) is/are correctly laid.
Tightening torque: see 1AZ in 32 33 STEERING WHEEL .
If necessary, modify shift paddles (5).

2007 BMW 335i
Fig. 87: Identifying Steering Wheel, Connectors, And Screw

Installation:
Align sport steering wheel using markings (1) to steering column and attach.
Replacement:
 Modify sport steering wheel cover / switches .
Fig. 88: Identifying Sport Steering Wheel Markings

STEERING WHEEL FOR AIRBAG

65 77...NOTES ON SCRAPPING BMW VEHICLES WITH GAS GENERATORS (CENTRAL AIRBAG
CONTROL UNIT, AIRBAG SYSTEM)
See NOTES ON SCRAPPING BMW VEHICLES WITH GAS GENERATORS (CENTRAL AIRBAG
2007 BMW 335i
CONTROL UNIT, AIRBAG SYSTEM) .
72 12...PROCEDURE AFTER AIRBAG DEPLOYMENT AS RESULT OF AN ACCIDENT
See PROCEDURE AFTER AIRBAG DEPLOYMENT AS RESULT OF AN ACCIDENT .
72 00... SAFETY REGULATIONS FOR HANDLING COMPONENTS WITH GAS GENERATORS
See SAFETY REGULATIONS FOR HANDLING COMPONENTS WITH GAS GENERATORS .
32 34 030 REMOVING AND INSTALLING / REPLACING AIRBAG UNIT (SPORT STEERING

WHEEL)
WARNING: Observe the following instructions to avoid any risk of injury by the
airbag unit.
 Comply with safety regulations for handling components with gas

generators.
 Do not exert any force on the airbag unit.
 Use only specified tools for releasing the airbag unit.
NOTE: Incorrect handling may result in triggering of the airbag unit and thereby cause
serious injury.
IMPORTANT: Steering wheel must be replaced if airbag unit has been triggered!
Follow procedure after airbag triggering.
Insert Torx screwdriver (T25) at an angle into concealed opening on reverse side of steering wheel until a spring
resistance is felt (approx. 1.5 cm).
Increase pressure on spring leg (concealed) using Torx screwdriver (T25) until airbag unit is unlocked.
Repeat procedure on other side.
Installation:
Make sure electrical leads are correctly positioned.
Snap airbag unit with uniform pressing force plane-parallel in direction of steering column shaft into steering
wheel.
2007 BMW 335i
Fig. 89: Electrical Leads Positions

Airbag unit may only be set down with the airbag itself facing upwards .
Tilt airbag unit forwards.
Disconnect plug connections and remove airbag unit.
Installation:
Connect plugs to connections of same color on airbag unit.

PUMP AND OIL SUPPLY

2007 BMW 335i
32 13 006 BLEEDING POWER STEERING UNIT
See BLEEDING POWER STEERING UNIT.
32 41... INSTRUCTIONS FOR REMOVING AND INSTALLING EAR CLIPS
 32 1 260
NOTE: The work steps are show on assorted components.
Ear clip must always be replaced.
To remove an ear clip, place special tool 32 1 260 at right angles to ear and cut ear open.

The ear clip can be fitted not only axially but also radially after the hook fastener has been opened.
2007 BMW 335i
Fig. 92: Ear Clip

Attach hook fastener and press ear together with special tool 32 1 260.

Side cutter of special tool 32 1 260 can be used in areas which are difficult to access.

IMPORTANT: Gap (A) max. 1 mm!

2007 BMW 335i
Fig. 95: Gap And Maximum Measurement

32 41... INSTRUCTIONS FOR USING SPECIAL TOOL 32 4 000
 32 4 000
 32 4 004
 32 4 005
 32 4 006
 32 4 011
 32 4 012
Depending on the pressure hose connection on the pump, the special tool 32 4 000 must be assembled.
1 = Connection, pump
2 = Connection, steering gear

2007 BMW 335i
Fig. 96: Special Tool (32 4 000), Pump Connection, Steering Gear Connection And Installation Directions
< EMPHASIZE >Pressure hose connection to pump with M14 x 1.5 banjo bolt:
Screw special tool 32 4 004 with M14 x 1.5 banjo bolt (1) and 2 sealing rings to special tool 32 4 000.
Screw special tool 32 4 011 onto pump and connect special tool 32 4 004.
Screw special tools 32 4 006 / 32 4 012 onto special tool 32 4 000 and connect pressure hose with M14 x 1.5
banjo bolts and 2 sealing rings.
Fig. 97: Banjo Bolt, Special Tools (32 4 006), (32 4 012), (32 4 011), (32 4 04) And Assembly
Pressure hose connection to pump with M16 x 1.5 banjo bolt:
Screw special tool 32 4 005 onto pump and connect special tool 32 4 004.
Screw special tool 32 4 006 onto special tool 32 4 000 and connect pressure hose with M16 x 1.5 banjo bolt and
2 sealing rings.
2007 BMW 335i
Fig. 98: Banjo Bolt, Special Tools (32 4 006),(32 4 005), (32 4 004) And Assembly
Pressure hose connection to pump with M16 x 1.5 union screw:
Connect special tool 32 4 004 to pump.
Screw special tools 32 4 006 / 32 4 005 onto special tool 32 4 000 and connect pressure hose.
Fig. 99: Banjo Bolt, Special Tools (32 4 006),(32 4 005), (32 4 004) And Assembly
32 41... NOTES ON HYDRAULIC LINE WITH QUICK-CONNECT COUPLING
1. Quick-connect coupling with ID marking

2007 BMW 335i
Fig. 100: Quick-Connect Coupling, Pipe, Plastic Ring, Markings And Assembly
Removing:
Push quick-connect coupling (1) against pipe (4) (thereby relieving strain on spring (2)).
Press plastic ring (3) into quick-connect coupling (1) and remove coupling (1).
Assembly:
Markings (K) on coupling (1) and pipe (4) must be flush.
Push quick-connect coupling (1) onto pipe (4) until a "click" can clearly be heard.
To check that quick-connect coupling (1) has been installed correctly, pull it back forcefully.
2. Quick-connect coupling with indication pins

2007 BMW 335i
Fig. 101: Quick-Connect Coupling, Indication Pins, Plastic Ring, Pipe, Transportation Lock And
Assembly
Removing:
Press plastic ring (2) into quick-connect coupling (1) and remove coupling (1).
Assembly:
When replacing hydraulic line: remove transportation lock (T).
Push quick-connect coupling (1) onto pipe (3) until both indication pins (4) can be seen and felt to point
outwards at outside diameter of housing.
To check that quick-connect coupling (1) has been correctly fitted, feel indication pins (4) at outside
diameter of housing. When correctly seated, indication pins (4) cannot be pressed into housing.
IMPORTANT: Coupling is not correctly engaged if both indication pins (4) fail to
protrude from housing. Leakage is thus unavoidable.
32 41 009 CHECKING FUNCTION OF POWER STEERING VANE PUMP

2007 BMW 335i
 32 4 000
system.
IMPORTANT: Prior to this check, first check all hose connections, the vane pump and the
power steering gear for leaks.
 Draw off and dispose off hydraulic fluid from fluid reservoir Observe country-specific waste-disposal
regulations
 Disconnect pressure line from vane pump
Connecting special tool:
Connect special tool 32 4 000 (refer to Notes on use) with new sealing rings to vane pump and pressure line.
1. Connection, vane pump

2. Connection, power steering gear
Fig. 102: Special Tool (32 4 000), Pump Connection, Steering Gear Connection And Installation
Directions
2007 BMW 335i
Checking pump pressure:
1. Close valve (A).

2. Open valve (B).
3. Fill and bleed hydraulic system
4. Start engine.
5. Heat hydraulic fluid to approx. 50 °C by moving steering wheel at increased engine speed.
6. Close valve (B) for max. 10 secs. and read off pressure.
7. Compare measured pressure with specified nominal pressure .
Replace vane pump if the nominal pressure is exceeded by more than 10 %.
Check belt tension if the nominal pressure is undershot by more than 10 %. Replace vane pump if belt
tension is OK.
Fig. 103: Special Tool (32 4 000), Valve (A) Close Position, Valve (B) Open Position And
Installation Directions
After installation:

32 41 033 REMOVING AND INSTALLING (REPLACING) POWER STEERING PUMP FOR POWER
STEERING GEAR WITH ACTIVE FRONT STEERING
Procedure is identical to:
 Removing and installing (replacing) power steering vane pump
NOTE: Also disconnect plug connection on ECO valve on back of power steering
2007 BMW 335i
pump.
32 41 060 REMOVING AND INSTALLING OR REPLACING POWER STEERING VANE PUMP

(N51, N52, N53)

corrosion.
A magnesium crankcase requires aluminium screws/bolts exclusively.
Aluminium screws/bolts must be replaced each time they are released .
The end faces of aluminium screws/bolts are painted blue for the purposes of
damage) .
Recycling:

 Remove belt pulley
 Remove radiator seal
Release hose clamp (1) and detach suction line (2) from vane pump.
Installation:
Align suction line by way of marking to connection on vane pump.

2007 BMW 335i
Fig. 104: Hose Clamp And Suction Line

Release bolt (1) and remove bracket with refrigerant line.
Release screws (2).
Installation:
Replace aluminium screws.
Observe screwing sequence.
Fig. 105: Bolt And Screws

Release banjo bolt (1) and disconnect pressure line.
Installation:
2007 BMW 335i
Replace all sealing rings (D).
Make sure pressure line is laid without tension and with sufficient spacing to adjoining components.
Release bolts (2) and remove vane pump towards bottom.
Fig. 106: Banjo Bolt And Bolts

Installation:
Replace aluminium screws.
Observe screwing sequence.
Screw-fastening sequence:
1. Secure vane pump with screws

2. Tighten side screws to 2 Nm
3. Tighten front screws to 2 Nm
4. Tighten down front screws to jointing torque and angle of rotation
5. Release screws at side and check screw fastening points for gap freedom
6. Tighten down side screws to jointing torque and angle of rotation
After installation:
2007 BMW 335i

32 41 100 REMOVING AND INSTALLING/REPLACING BELT PULLEY ON VANE PUMP FOR

POWER STEERING
NOTE: Carry out preliminary work as described in the document "Replacing drive belt
".
Slacken bolts (1)
Relieve tension on drive belt and remove from belt pulley (2).
Unscrew bolts (1) and remove belt pulley (2).
Installation:
Lettering on belt pulley (2) must point forwards.
Fig. 107: Bolts And Belt Pulley

32 41 250 REMOVING AND INSTALLING / REPLACING FLUID RESERVOIR FOR POWER

STEERING
Recycling:
2007 BMW 335i
M57T2 335d:
 Unclip water hose from coolant expansion tank
M57T2 335d:
 Unclip coolant hose on coolant expansion tank
Release screw (1).
NOTE: If necessary, raise and/or turn fluid reservoir in order to gain better access to
hose clamps.
Unfasten hose clips.
Disconnect suction line and radiator return line from fluid reservoir.
Lift out fluid reservoir.
Fig. 108: Screw And Removal Direction

Installation:
2007 BMW 335i
After installation:

32 41 253 REMOVING AND INSTALLING / REPLACING FLUID RESERVOIR FOR POWER

STEERING WITH ACTIVE FRONT STEERING
Recycling:
M57T2 335d:
 Unclip water hose from coolant expansion tank
Release screw (1).
NOTE: If necessary, raise and/or turn fluid reservoir in order to gain better access to
hose clamps.
Unfasten hose clips.
Disconnect suction line and radiator return line from fluid reservoir.
Lift out fluid reservoir.

2007 BMW 335i
Fig. 109: Screw And Removal Direction

After installation:

32 41 311 REPLACING INTAKE LINE FOR POWER STEERING
Recycling:

Release hose clamp (1) and detach suction line (2) from fluid reservoir.
Installation:
Make sure hydraulic line is laid without tension and with sufficient spacing to adjoining components.
2007 BMW 335i

Expose suction line up to connection on vane pump.
Release hose clamp (1) and detach suction line (2) from vane pump.
Installation:
Markings (3) on suction line and vane pump must match up.
If a marking is missing, it is important to ensure when installing the hydraulic line that it is laid without tension
and with sufficient spacing to adjoining components.
Fig. 111: Hose Clamp, Markings And Suction Line

After installation:

2007 BMW 335i
32 41 332 REPLACING DELIVERY LINE FOR POWER STEERING
system.
Recycling:

 Remove radiator
Release banjo bolt and detach pressure line from vane pump.
Installation:

2007 BMW 335i
Fig. 112: Banjo Bolt

Expose pressure line up to connection on power steering gear.
Release banjo bolt and disconnect pressure line.
Installation:

After installation:
2007 BMW 335i

32 41 332 REPLACING PRESSURE LINE FOR POWER STEERING (AWD)
WARNING: DANGER OF POISONING if oil is ingested/absorbed through the skin!
RISK OF INJURY if oil comes into contact with eyes and skin!
system.
Recycling

 Remove FRONT UNDERBODY PROTECTION
Release banjo bolt and detach pressure line from vane pump.
Installation:
Tightening torque, see 8AZ in 32 41 PUMP AND OIL SUPPLY

2007 BMW 335i
Fig. 114: Locating Pressure Line Banjo Bolt

Expose pressure line up to connection on power steering gear.
Release banjo bolt (1) and remove pressure line (2).
Installation:
Tightening torque, see 9AZ in 32 41 PUMP AND OIL SUPPLY .
Fig. 115: Locating Pressure Line Banjo Bolt

2007 BMW 335i
After installation

32 41 341 REPLACING COOLER RETURN LINE FOR POWER STEERING
system.
Recycling:

 N51, N52, N53, N54: Remove intake filter housing
 M47T2, M57T2: Remove intake duct
Remove fluid reservoir from bracket.
Release hose clamp (1) and detach cooler return line (2) from fluid reservoir.
Installation:

2007 BMW 335i

Expose cooler return line up to connection on power steering coil.
Release quick-connect coupling and seal power steering coil connection with a suitable plug.
Installation:
Fig. 117: Quick-Connect Coupling

After installation:

32 41 351 REPLACING RETURN LINE FOR POWER STEERING

2007 BMW 335i
system.
Recycling:

Release quick-connect coupling and seal cooling coil connection with a suitable plug.
Installation:
Fig. 118: Identifying Return Line On Cooling Loop

Expose return line up to connection on power steering gear.

2007 BMW 335i
Release banjo bolt and disconnect return line.
Installation:

After installation:

32 41 351 REPLACING RETURN LINE FOR POWER STEERING (AWD)
WARNING: DANGER OF POISONING if oil is ingested/absorbed through the skin!
RISK OF INJURY if oil comes into contact with eyes and skin!
system.
Recycling

2007 BMW 335i

 Remove FRONT UNDERBODY PROTECTION
Release QUICK-CONNECT COUPLING and seal cooling coil connection with a suitable plug.
Installation:
Make sure return line is laid without tension and with sufficient spacing to adjoining components.
Fig. 120: Identifying Return Line On Cooling Loop

Expose return line up to connection on power steering gear.
Release banjo bolt (1) and remove return line (2).
Installation:
Make sure return line is laid without tension and with sufficient spacing to adjoining components.
Tightening torque, see 10AZ in 32 41 PUMP AND OIL SUPPLY .

2007 BMW 335i
Fig. 121: Locating Return Line Banjo Bolt

After installation

ELECTRONIC POWER STEERING

32 10 005 ADJUSTMENT FOR ACTIVE FRONT STEERING
See ADJUSTMENT FOR ACTIVE FRONT STEERING.
32 43 010 REMOVING AND INSTALLING/REPLACING CONTROL UNIT FOR ACTIVE FRONT

STEERING
Protection).

 Remove front left wheel arch cover (rear section)
Release screw (1) and remove grounding cable.
Open cable tie (see arrow in illustration).

2007 BMW 335i
Installation:
Replace faulty cable holder (4).
Fig. 122: Screws, Plugs, Cable Tie And Cable Holder

Unscrew nut (1).
For tightening torque refer to 32 43 1AZ in 32 43 ELECTRONIC POWER STEERING .
Release screw (2).
For tightening torque refer to 32 43 1AZin 32 43 ELECTRONIC POWER STEERING .
Remove active front steering control unit (3).

2007 BMW 335i
Fig. 123: Nut, Screw And Steering Control Unit

After installation:
 Replacement only: Carry out programming/coding

 Carry out adjustment for active front steering
TROUBLESHOOTING
32 90... TROUBLESHOOTING ON ELECTRIC STEERING GEAR (EPS)
Read fault memory.
ELECTRIC STEERING GEAR (EPS) TROUBLESHOOTING CHART

Fault Cause Remedy
Failure of power-assisted 1. Contacts corroded NOTE:
steering / clear reduction of Check insulation of connecting
power-assisted steering when cable for damage, replace part if
stationary necessary
 Replace contacts and plug

housing
 Clean contacts on steering
gear, replace steering gear
if necessary
2. Insulation of connecting cable Check insulation of connecting
damaged cable for damage, replace part if
necessary
Refer to troubleshooting on front axle
Excessive steering wheel Screws at lower section of steering Replace screws and tighten down
play/steering wheel shake shaft to steering gear/steering (refer to Removing and
2007 BMW 335i
column loose installing/replacing lower

section of steering shaft)
Journal of tie rod end deformed Replace steering gear and tie rod
ends
Tie rod end worn Check steering gear rack; if
necessary, replace steering gear
Check tie rods, replace if
necessary
Replace tie rod end
Steering gear rack damaged Replace steering gear
refer to troubleshooting on front axle
Steering wheel inclination Tie rod end worn Replace tie rod end
Front axle alignment incorrectly Carry out chassis/wheel
adjusted alignment check, adjust toe/track
if necessary
Vehicle pulls Steering angle sensor adjustment Carry out steering angle sensor
failed adjustment
Steering column switch cluster Check mounting for steering
faulty column switch , replace if
necessary
Interference noise when steering Spindle surface dirty or corroded Replace steering gear
through (under load) (caused by damaged gaiter)
NOTE: In a warranty case you must always provide a fault memory printout, even
where there is no fault memory
32 90... TROUBLESHOOTING ON STEERING
Observe troubleshooting on front axle and diagnosis help for steering (SI).
STEERING TROUBLESHOOTING CHART

Fault Cause Remedy
Excessive steering wheel Screws at lower section of steering Replace screws and tighten down
play/steering wheel shake shaft to steering gear/steering (refer to Removing and
column loose installing/replacing lower
section of steering shaft)
Bolt connection, universal Replace and tighten down bolts
joint/double joint, to lower section
of steering shaft/steering
gear/steering column loose
Journal of tie rod end deformed Replace steering gear and tie rod
ends
Tie rod end worn Check steering gear rack; if
2007 BMW 335i
necessary, replace steering gear

Check tie rods, replace if
necessary
Replace tie rod end
Steering gear rack damaged Replace steering gear
Steering wheel inclination Tie rod end worn Replace tie rod end
Front axle alignment incorrectly Carry out chassis/wheel
adjusted alignment check, adjust toe/track
if necessary
2007 BMW 335i
2007 SYSTEM WIRING DIAGRAMS BMW - 335i
2007 SYSTEM WIRING DIAGRAMS
BMW - 335i
USING MITCHELL1'S WIRING DIAGRAMS

For information on using these wiring diagrams, see USING MITCHELL1'S SYSTEM WIRING
DIAGRAMS article.
ACTIVE BODYWORKS
2007 BMW 335i
Fig. 1: Active Bodyworks Circuit

2007 BMW 335i
AIR CONDITIONING
2007 BMW 335i
Fig. 2: Automatic A/C Circuit (1 of 2)

2007 BMW 335i
Fig. 3: Automatic A/C Circuit (2 of 2)

2007 BMW 335i
Fig. 4: Independent Heating Circuit

2007 BMW 335i
Fig. 5: Manual A/C Circuit

2007 BMW 335i
ANTI-LOCK BRAKES
2007 BMW 335i
Fig. 6: Anti-lock Brakes Circuit

2007 BMW 335i
ANTI-THEFT
2007 BMW 335i
Fig. 7: Access/Start Circuit (1 of 2)

2007 BMW 335i
Fig. 8: Access/Start Circuit (2 of 2)

2007 BMW 335i
Fig. 9: Anti-theft Circuit (1 of 2)

2007 BMW 335i
Fig. 10: Anti-theft Circuit (2 of 2)

2007 BMW 335i
BODY CONTROL MODULES

2007 BMW 335i
Fig. 11: Body Control Modules Circuit (1 of 2)

2007 BMW 335i
Fig. 12: Body Control Modules Circuit (2 of 2)

2007 BMW 335i
COMPUTER DATA LINES

2007 BMW 335i
Fig. 13: Computer Data Lines Circuit

2007 BMW 335i
COOLING FAN
2007 BMW 335i
Fig. 14: Cooling Fan Circuit

2007 BMW 335i
CRUISE CONTROL
2007 BMW 335i
Fig. 15: Cruise Control Circuit

2007 BMW 335i
DEFOGGERS
2007 BMW 335i
Fig. 16: Defoggers Circuit

2007 BMW 335i
ELECTRONIC POWER STEERING

2007 BMW 335i
Fig. 17: Electronic Power Steering Circuit

2007 BMW 335i
ENGINE PERFORMANCE
3.0L
2007 BMW 335i
Fig. 18: 3.0L, Engine Performance Circuit (1 of 4)

2007 BMW 335i

2007 BMW 335i

2007 BMW 335i

2007 BMW 335i
EXTERIOR LIGHTS
2007 BMW 335i
Fig. 22: Back-up Lamps Circuit

2007 BMW 335i
Fig. 23: Exterior Lamps & Trailer Connector Circuit (1 of 3)

2007 BMW 335i

2007 BMW 335i

2007 BMW 335i
GROUND DISTRIBUTION
2007 BMW 335i
Fig. 26: Ground Distribution Circuit (1 of 4)

2007 BMW 335i

2007 BMW 335i

2007 BMW 335i

2007 BMW 335i
HEADLIGHTS
2007 BMW 335i
Fig. 30: Adaptive Front Lighting Circuit (1 of 2)

2007 BMW 335i
Fig. 31: Adaptive Front Lighting Circuit (2 of 2)

2007 BMW 335i
Fig. 32: Headlamps Circuit, W/ Xenon Lamps (1 of 2)

2007 BMW 335i
Fig. 33: Headlamps Circuit, W/ Xenon Lamps (2 of 2)

2007 BMW 335i
Fig. 34: Headlamps Circuit, W/O Xenon Lamps

2007 BMW 335i
HORN
2007 BMW 335i
Fig. 35: Horn Circuit

2007 BMW 335i
INSTRUMENT CLUSTER
2007 BMW 335i
Fig. 36: Instrument Cluster Circuit

2007 BMW 335i
INTERIOR LIGHTS
2007 BMW 335i
Fig. 37: Courtesy Lamps Circuit, W/ Roof Function Center Except Wagon (1 of 2)
2007 BMW 335i
Fig. 38: Courtesy Lamps Circuit, W/ Roof Function Center Except Wagon (2 of 2)
2007 BMW 335i
Fig. 39: Courtesy Lamps Circuit, W/O Roof Function Center

2007 BMW 335i
Fig. 40: Courtesy Lamps Circuit, Wagon W/ Roof Function Center (1 of 2)

2007 BMW 335i
Fig. 41: Courtesy Lamps Circuit, Wagon W/ Roof Function Center (2 of 2)

2007 BMW 335i
Fig. 42: Instrument Illumination Circuit

2007 BMW 335i
MEMORY SYSTEMS
2007 BMW 335i
Fig. 43: Driver"s Memory Seat Circuit, Coupe (1 of 2)

2007 BMW 335i
Fig. 44: Driver"s Memory Seat Circuit, Coupe (2 of 2)

2007 BMW 335i
Fig. 45: Driver"s Memory Seat Circuit, Except Coupe (1 of 2)

2007 BMW 335i
Fig. 46: Driver"s Memory Seat Circuit, Except Coupe (2 of 2)

2007 BMW 335i
Fig. 47: Passenger"s Memory Seat Circuit (1 of 2)

2007 BMW 335i
Fig. 48: Passenger"s Memory Seat Circuit (2 of 2)

2007 BMW 335i
Fig. 49: Steering Column Memory Circuit

2007 BMW 335i
NAVIGATION
2007 BMW 335i
Fig. 50: Navigation Circuit, Base Radio

2007 BMW 335i
Fig. 51: Navigation Circuit, Hifi Radio (1 of 2)

2007 BMW 335i
Fig. 52: Navigation Circuit, Hifi Radio (2 of 2)

2007 BMW 335i
Fig. 53: Navigation Circuit, Top Hifi Radio (1 of 2)

2007 BMW 335i
Fig. 54: Navigation Circuit, Top Hifi Radio (2 of 2)

2007 BMW 335i
Fig. 55: Parking Assistant Circuit

2007 BMW 335i
POWER DISTRIBUTION
2007 BMW 335i
Fig. 56: Power Distribution Circuit (1 of 5)

2007 BMW 335i

2007 BMW 335i

2007 BMW 335i

2007 BMW 335i

2007 BMW 335i
POWER DOOR LOCKS

2007 BMW 335i
Fig. 61: Power Door Locks Circuit (1 of 2)

2007 BMW 335i
Fig. 62: Power Door Locks Circuit (2 of 2)

2007 BMW 335i
POWER MIRRORS
2007 BMW 335i
Fig. 63: Electrochromic Mirror Circuit

2007 BMW 335i
Fig. 64: Power Mirrors Circuit, W/ Heated Mirrors

2007 BMW 335i
Fig. 65: Power Mirrors Circuit, W/O Heated Mirrors

2007 BMW 335i
POWER SEATS
2007 BMW 335i
Fig. 66: Driver Power Seat Circuit

2007 BMW 335i
Fig. 67: Heated Seats Circuit

2007 BMW 335i
Fig. 68: Lumbar Circuit

2007 BMW 335i
Fig. 69: Passenger Power Seat Circuit

2007 BMW 335i
Fig. 70: Sport Seats Circuit

2007 BMW 335i
POWER TOP/SUNROOF
2007 BMW 335i
Fig. 71: Sunroof Circuit

2007 BMW 335i
POWER WINDOWS
2007 BMW 335i
Fig. 72: Power Windows Circuit (1 of 2)

2007 BMW 335i
Fig. 73: Power Windows Circuit (2 of 2)

2007 BMW 335i
Fig. 74: Rear Window Sun Shade Circuit

2007 BMW 335i
RADIO
2007 BMW 335i
Fig. 75: Radio Circuit, Base Radio M-ASK-BO or CCC-BO

2007 BMW 335i
Fig. 76: Radio Circuit, Hifi Radio M-ASK-BO or CCC-BO (1 of 2)

2007 BMW 335i
Fig. 77: Radio Circuit, Hifi Radio M-ASK-BO or CCC-BO (2 of 2)

2007 BMW 335i
Fig. 78: Radio Circuit, Hifi Radio RAD or RAD2-BO (1 of 2)

2007 BMW 335i
Fig. 79: Radio Circuit, Hifi Radio RAD or RAD2-BO (2 of 2)

2007 BMW 335i
Fig. 80: Radio Circuit, Top Hifi Radio (1 of 2)

2007 BMW 335i
Fig. 81: Radio Circuit, Top Hifi Radio (2 of 2)

2007 BMW 335i
SHIFT INTERLOCK
2007 BMW 335i
Fig. 82: Shift Interlock Circuit

2007 BMW 335i
STARTING/CHARGING
2007 BMW 335i
Fig. 83: Charging Circuit

2007 BMW 335i
Fig. 84: Starting Circuit

2007 BMW 335i
SUPPLEMENTAL RESTRAINTS
2007 BMW 335i
Fig. 85: Supplemental Restraints Circuit (1 of 2)

2007 BMW 335i
Fig. 86: Supplemental Restraints Circuit (2 of 2)

2007 BMW 335i
TRANSMISSION
2007 BMW 335i
Fig. 87: A/T Circuit

2007 BMW 335i
TRUNK, TAILGATE, FUEL DOOR

2007 BMW 335i
Fig. 88: Trunk, Tailgate, Fuel Door Circuit

2007 BMW 335i
WARNING SYSTEMS
2007 BMW 335i
Fig. 89: Tire Pressure Monitoring Circuit

2007 BMW 335i
WIPER/WASHER
2007 BMW 335i
Fig. 90: Wiper/Washer Circuit

E92 E93 Repair

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

E92 E93 Repair

Uploaded by

Copyright:

Available Formats

2007 BMW 335i

ACCESSORIES AND EQUIPMENT Audio, Navigation and Anti-Theft - Repair Instructions

ACCESSORIES AND EQUIPMENT

Audio, Navigation and Anti-Theft - Repair Instructions

Fig. 1: Overview Of Audio Components (Hifi System)

65 00.. OVERVIEW OF AUDIO COMPONENTS (TOP HIFI SYSTEM)

Fig. 2: Overview Of Audio Components (Top Hifi System)

65 00.. OVERVIEW OF AUDIO COMPONENTS (STEREO SYSTEM)

Fig. 3: Overview Of Audio Components (Stereo System)

NOTE: To ensure trouble-free CD changer operation, ensure both suspension springs

To avoid premature contamination of the CD changer, make sure the magazine

NOTE:  Observe the following repair instructions if the magazine cannot be

Observe Notes on handling CD changers

 E60, E61, E63, E64:

Remove CD changer magazine

Ejection via self-diagnosis

 E87, E90, E91:

CD changer must be sent in

Remove cover cap (1) from CD changer (2).

Fig. 4: Identifying Cover Cap And CD Changer

Fig. 5: Identifying CD Changer And Suspension Spring

Courtesy of BMW OF NORTH AMERICA, INC.

65 11... REMOVING AND INSTALLING/REPLACING SATELLITE TUNER (US VERSION ONLY)

Necessary preliminary work

Fig. 6: Identifying Violet Antenna Connection And Black Antenna Connection

Record SID number (1) of the removed device.

Fig. 7: Identifying SID Number

Carry out VEHICLE PROGRAMMING/ENCODING .

65 11 070 REMOVING AND INSTALLING/REPLACING CD CHANGER (COUPE)

Necessary preliminary tasks:

 Disconnect Battery Negative Lead

NOTE: Follow instructions for Handling Optical Fibres. .

Release screws (1).

Remove CD changer (2) complete with holder.

Fig. 8: Identifying Screws And CD Changer

Fig. 9: Identifying Screws, Holder And CD Changer

65 11 072 REMOVING AND INSTALLING/REPLACING CD CHANGER (CONVERTIBLE)

NOTE: Follow instructions for Handling Optical Fibres. .

Necessary preliminary tasks:

 Disconnect Battery Negative Lead

Release screws (1).

Disconnect plug connections (2).

Remove CD changer (3) complete with holder.

Fig. 10: Identifying Screws, Connector, And CD Changer

Fig. 11: Identifying CD Changer Bracket And Screws

65 11 080 REMOVING AND INSTALLING/REPLACING RADIO RECEIVER

Necessary preliminary tasks:

 Disconnect Battery Negative Lead

NOTE: Comply with notes and instructions on Handling Optical Waveguides.

Release screws (1).

Pull back radio receiver (2) slightly.

Disconnect associated plug connections and remove radio receiver (2).

For US version only:

Refer to Replacing satellite tuner!

Carry out PROGRAMMING/ENCODING

STEREO RADIO, AMPLIFIER

Fig. 14: Overview Of Audio Components (HiFi System)

6500... OVERVIEW OF AUDIO COMPONENTS (TOP HIFI SYSTEM)

Fig. 15: Overview Of Audio Components (Top HiFi System)

6500... OVERVIEW OF AUDIO COMPONENTS (STEREO SYSTEM)

Fig. 16: Overview Of Audio Components (Stereo System)

65 12 230 REMOVING AND INSTALLING/REPLACING DAB TUNER

NOTE: Follow Instructions For Handling Optical Fibres.