16 00 005 Draining and filling fuel tank 1—Drawing off the fuel tank Contact with hazardous fluids. Hazardous to healtht + Note and folow safety information on containers, * Conduct all work in appropriate personal protective equipment only. Working on fuel system. Risk of firel Danger of explosion! ‘+ When working on the fuel system, make sure that the workbay is sufficiently ventilated, e.g, using extraction unt + Tightly sealoff open lines and connections; collect any escaping fuel drectly atthe point of ext. + No fire, sparks, open flames or smoking (Gs + 000 6 oe Additional Information Overview of Special Tools Open tue! filer cap. Insert special too! into fuel filer neck, ‘The special too! has two different diameters for petrol and diesel vehicles, Push the suction hose (1) of the extractor unt through the specialtool and into the fuel filer neck. necessary, slightly turn the suction hose. For the extractor unt: see BMW service workshop equipment. The insertion length of the suction hose is 135 cm. Statt engine and allow to run, so that the electric fuel pump is running, ‘This will ensure that the fuel is pumped by the suction jet pump from the lefthand side of the fuel tank to the right hand-side. Draw off uel wth the extractor unit as far as possible. In the process, track the drawing off of the fuel on the fuel gauge inthe instrument cluster. Insert special tool into fuel filer neck. Special tool has two different diamaters: for petrol and for diesel fuel. Slide the suction hose (1) of the extractor unt about 40 cm nto the fuel filer neck. necessary, sightly turn the suction hose. Filfuel fom suction extractor unt. {After completing the work and before starting the engine forthe fst time: Filthe fuel tank by the fuel flerneck with a minimum of § lof fuel16 11030 Removing and installing fuel tank Prerequisite ‘+ Vehicles without stationary heating! PRELIMINARY WORK 1 —Drawing off the fuel tank Contact with hazardous fluids. Hazardous to health! * Note and folow safety information on containers, *+ Conduct all work in appropriate personal protective equipment only Working on fuel system, Risk of fire! Danger of explosion! + When working on the fuel system, make sure that the workbay is sufficiently ventilated, e.g. using extraction unit + Tightly sealoff open lines and connections; collect any escaping fuel drectly at the point of exit + No fire, sparks, open flames or smoking. pen fuel filer cap. Insert special tool into fuel filer neck. The special tool has two different diameters for petrol and diesel vehicles, Push the suction hose (1) of the extractor unt through the specialtool and into the fuel ler neck. necessary, slightly tum the suction hose. Forthe extractor unt: see BMW service workshop equipment. The insertion length of the suction hose is 135 em. Start engine and allow to run, so that the electric fuel pump is running. 151000254 This wil ensure that the fuel is pumped by the suction jet pump from the leftchand side of the fuel tank to the right hand-side. Draw off uel with the extractor unit as far as possible. In the process, track the drawing off of the fuel on the fuel gauge in the instrument cluster. 2.Remove the connecting support from the tunnel + Remove screws (arrows). + Ifinstalled: Loosen clamp (1). + Loosen screws (2). + Guide out and remove connecting support (3) on the tunnel'3—Remove complete exhaust system Hot surfaces. Risk of burning! + Perform all work only on components that have cooled down, Component with heavy weight. Danger of injury! Note component's centre of gravity. ‘Support component using a jack Secure component against falling off the jack Heavy component. Heavy components can lead to injury or damage. Remove and install heavy components with the aid of another person/other persons. ‘+ Equipment specification 1 (ribbon clamp) Detach the ribbon clamp (1). ‘+ Equipment specification 2 (V-clips) Unfasten clamp (1)+ Loosen nut (1) + Release nut (1) on the rear axle support. ‘+ Uniock plug connection (1) and disconnect. + Loosen nuts (2). ‘+ Lower and remove the exhaust system (3) with the assistance of a second person. ‘+ Loosen bolts and nuts (arrows) + Remove heat shield (1) + Loosen bolts and nuts (arrows). ‘+ Remove heat shield (1) 5 — Remove rear underbody protection+ Version 4: Remove screws (arrows). Feed out the rear underbody protection (1). B+ Version 2: Remove screws (arrows). Guide out rear underbody protection (1) and remove it. ‘+ Support the transmission using special tools 0.495 498 (23 4 050) and 22taor. + Secure the transmission with the tensioning strap (1). ‘+ Loosen screws (1). + Loosen screw (2) ‘+ Remove transmission cross member (3) and lower the transmission slightly, 7 — Completely removing the propeller shaft (plug-in - rear flexible disc)Pees Damage to propeller shaft during removal. Non-observance of the removal guidelines for the propeller shaft on the rear axle differential may cause severe damage. Do not disassemble the three-hole flange, flexible disc and propeller shaft. The three-hole flange to the rear axle diferential is balanced with the flexble disc and propeller shatt Loosen the recessed nut against the direction of travel in clockwise direction. The propeller shaft must be loosened on the recessed nut only and exclusively in the direction of rotation otherwise the antitwist lock of the bihexagonal ange nut is damaged, In the event of a damaged antitwist lock on the bichexagonal lange nut: Replace the rear axle diferential, + In order to avoid a humming noise of the drivetrain ater reinstaling the propeller shat: = The flexible disc connection (1) on the front at the propeller shaft must ‘be marked in ane plane with the flexible disc (2) and the three-bolt flange (8) before loosening, ~ During installation the three-bott flange (3) must be forced back together again withthe flexible disc (2) inthe same position ‘+ Remove screws (arrows) + Loosen screws (1). ‘+ Vehicles with a narrow universal joint: + Using the special tool 2 464 898 and a suitable tool (2), secure the propeller shaft (1) to the centre universal joint against twisting+ Vehicles with a broad universal cin: + Secure the propeller shaft against twisting atthe central universal joint Using a suitable tool (2) Do not remove the bolts (1) of the centre mount completely untilthe recessed nut has been opened. Beene Damage to rear axle differential. Non-observance of the removal and installation guidelines may ‘cause severe damage to the rear axle differential. Do not use the double hexagon head flange nut as counter support Loosen the recessed nut in clockwise direction, arrow, using special tools 0 495 554 (93 5 070) and 20 the direction of the Remove mounting cp (1) and gasket (2) + Remove recessed nut (1). 8 Removing the rear right wheel> Removing the wheel + Invehicies with M Carbon o®, coramicbrako: Tho whool ’ » assembly jack must be used to y remove the wheel (see | workshop equipment). This process is intended to pprovent damage to the brake disc. Po cuoot * Ifseveral wheels are removed simultaneously: Use a piece of chak to mark on each tyre the axle and side on which the comesponding wheels fited ‘+ Release the whee! bolts (arrows) crosswise and remove the wheel + To release and tighten wheel bolts with a security code: Use a suitable adapter from the tool set ‘9— Removing rear wheel arch cover Rod ‘To provide a better overview: Schematic diagram with partially hidden components, + Loosen screws (1). + Loosen nuts (2). + Guide the whe: arch cover (3) out. 10 Removing seat bench+ Disengage the seat bench (1) in area (2) in an upward direction. + Feed out the seat belt buckle (3) from the seat bench, ‘+ Pullthe seat bench (1) further forward. + Rolease screw (2) on the ond iting and guid out bek (2) Note: there isa belt lock onthe bet the serew on the endfiting must not be released + Htnecessary, dsconnect ihe present plug connections + Litthe seat bench (1) out of the vehicle 11 —Lock delivery unit (vehicles without parking heater) Working on fuel system, Risk of fir! Danger of explosion! ‘+ When working on the fuel system, make sure that the workbay is sufficiently ventilated, e.g. using extraction unt. ‘+ Tighty sealoff open tines and connections; collect any escaping fuel directly atthe point of ext ‘+ No fire, sparks, open ames or smoking, Lc ee Collect and dispose of emerging fuids. Observe country-specific waste disposal ragulations. ‘+ Expand the floor trims in the area (1) in direction of arrow,MAIN WORK + Tumthe ling cap (1) in the direction of arrow (anti clockwise). ‘+ Unlock the locking tab (1) in the direction of the arrow. ‘+ Oporate the tab (2)and pulloffthe connector housing ‘+ Unlock and pulloff snap fastener (1) + Equipment specification with optional equipment 1AK (external fuel filter). Unlock and pull off the snap fasteners (1). necessary, unlock and disconnect the snap fastener (2) for the auxilary heater. 12— Remove fuel tank+ Loosen hose clamp (1). ‘+ Pulloffrubber hose from fuel tank in direction of arrow, ‘+ Unlock and disconnect snap fastener (1). + Detach the fuel filer neck breather pipe from the brackat (2) ‘+ During lowering of the fuel tank: Feed the fuel filer neck breather pipe through the body n the direction of the arrow. + Heavily support fuel tank(3). ‘+ Unscrew the screws (1) and remove the retaining straps. + Unscrew the nut (2) and lower the fuel tank (3). ‘+ Raise the fuel tank (8) while feeding the fuel flor neck breather pipe through the rear axle support. ‘+ Guide the fuel flor neck breather pipe through the body into the whee! arch. ‘+ Raise the fuel tank (3) to the installation position while paying attention to the installation position ofthe fuel ler neck breather pipe. + Renew nut (2) arts: Nut + Fit nut (2) and tighten. Ful tank to body Nut Me Renewnut. Tightening 19Nm torque + Renew screws (1). Parts: Bolts ‘+ Mount the retaining straps and position and tighten the screws (1). Fuel tank retaining strap to body MB screw Renewscrews. Tightening 19Nm torque‘+ Attach the fus! filer nack breather pipe in the brackets (1). *+ Position snap fastener (2) and lock. ‘+ Mount rubber hose on fuel tank in direction of arrow, ‘+ Renew the hose clamp (1) Parts: Hose clamp Filling hose on fuel tank Hose clamp Replace hose clamp. ‘Tightening 4m torque POSTPROCESSES 14— Connecting delivery unit (vehicles without stationary heating) Working on fuel system. | Risk of fia! Danger of explosion! 1 When working on the fuel system, make sure that the workbay is sufficiently ventilated, e.g. using extraction unit Tightly sealoff open tines and connections; collect any escaping fuel directly at the point of ext. No fire, sparks, open flames or smoking, TECHNICAL INFORMATION isposal regulations. Lc Allnew delivery units are delivered with the stationary healing system in the equipment specification. For these vehicles, the connection on the flange lid must be closed with a locking coupling. Locking coupling must be ordered separately, see Electronic Parts Catalogue.15 Installing rear seat bench ‘+ Position snap fastener (1) and lock. ‘+ Connect the plug connection (2). + Fit the plug connection and latch i + Lock retaining tab (1) in the direction of the arow. ‘+ Renew the sealing cap of the floor panel Parts: Sealing cap of the floor panel There is a risk of leakage ifthe sealing cap of he floor panelis reused. ‘+ Coat gasket in area (1) using Carbatlo KSP 105 lubricant (see Electronic Parts Catalogue). + Latch sealing cap (1) up to the Imit position in the direction of the arrow. Mark (2) must point to the front in the direction of travel. ‘+ Lock the carpet in area (1).‘+ Li the seat bench (1) into the vehicle. *+ Insert the seat belt (3). ‘+ Renew the screw (2) Parts: Screw + Tighten down screw (2) Rear upper seat bel to bottom body Sorew Renew screw. Tightening 42Nm torque + Connect available connectors. + Insert seat bench (1). ‘+ Thread seat bolt buckles (3) into the seat bench. + Engage the seat bench (1) in the area (2). 16 — Removing the rear whe Moe To provide a better overview: Schematic diagram with partially hidden components, ‘+ Guide the wheel arch cover (3) in, + Tighten the screws (1). ‘+ Tighten nuts (2). 17— Mounting the rear right whee! > Mounting the wheelEcc iene ‘The contact surface between the brake disc and the whee rim must be clean and free from oil and grease. There is otherwise a risk of the wheel becoming loose at alater time. ‘+ Remove din, grease residues and corrosion from the contact surface with adil and the special ool2 344 011, Do not operate special tool 2 344 011 with an impact screwdriver. ‘+ Degrease the contact surfaces with the universal cleaner (see BMW. Group Parts) ‘+ In the event of grease residue in the area of the wheel bolt holes, remove and clean the brake disc. + Remove dit, grease residues and corrosion from the contact surface with a dill and the special tool 2 344 011. Do not operate special tool 2344 011 with an impact screwdriver. ‘+ Degrease the contact surfaces with the universal cleaner (see BMW Group Parts) ‘+ Check that the mounting bolt (1) for the brake disc is securely seated. ‘The mounting bok (1) for the brake disc may not protrude under any circumstances on the contact surface (2) between the brake disc and the wheel rim, Brake disc to front wheel hub Me Renew screw, Tightening 16Nm torque Brake disc to rear wheel hub Me Renew sorew, Tightening 16Nm torque ‘+ Thinly grease the wheel centring (1) in the wheel rm. Expendable materials Brake bbc paste a0, ssteztseest sTUetredo Unt TUrunbers Bap Eee erred cor bveog eapebot. 1009, steztseese 59, sszso14ca39 uwp fe 6 . a Ny oS ef © hh FAO ‘+ Lightly grease the front and rear whee! hubs in this area (1) to protact fom corrosion Expendable materials Brake block paste 93192158851 *TU=Trade Unit. TU numbers cannot be ordered! For invoicing 83192188852 purposes only 83230140233, + Invehicles with M Carbon ‘ceramic brake: The whee! assembly jack must be used to install the wheel (see workshop equipment) This process is intended to prevent damage to the brake disc,Ecc iene Never use impact screwdrivers or electric screwdrivers to screw in and tighten the wheel bots. |The wheel rim must rest uniomiy against the brake disc 1 Inthe case of nomoriginal BMW wheelbottshvneel ms, t may be necessary to retighten the wheel bols on account of setting propertos (‘eter the documentation trom the manutacture. Do not apply ollto new whee! bolts. ‘+ Renew corroded whee! bolts Parts: Wheel bolts + Clean the whe: + Check wheel bolts and threads for damage, renew the whee! bolts if necessary. ‘+ Join and tighten the wheel bolts (arrows). Wheel bolts Mi4/SW17 — Screwinwheelbolts and Tightening 140/Nm evenly tighten crosswise by torque hand in orderto centre the whee rim, Tighten wheelbotts to the prescribed tightening torque with a calibrated torque wrench ina crosswise Check arom sequence. Check allthe wheel bolts in the same order or retighten to the prescribed tightening torque again. bolts. 18— Completely installing the propeller shaft (plug-in - rear flexible disc) Pees Damage to the propeller shaft during installation. Non-observance of the installation guidelines for the propeller shaft on the rear axle differential may cause severe damage. Always renew the recessed nut on the rear axle differential. Screw locking must be available, Strictly observe a minimum hardening time of two hours after having screwed in time may be longer at lower temperatures.+ Observe following instalation sequence ~ Position propeller shatt on transmission, ~ Position the propeller shaft atthe rear axle differential + Position centre mount ‘+ Observe the following screwing sequence: Insert nut Flexible disc to transmission Centre mount ‘+ Check the centering (artow) for damage, renew i required. ‘+ Apply a thin coat of grease to the soft centring (1), ifnecessary Expendable materials Lubricating grease Olistamaly2LN 1009, 83 190447919 584 LO Tube + Hard centring (2) must not be greased. + Clean al residue trom the insert collar(1) of the flange nut and the gearing ‘on the bevel pinion (2) and degrease them. ‘+ Top up the collar insert (1}with grease. Expendable materials Lubricating grease Optitemp HT'1 LF 50 9, 83230417754 TubeBeaune Damage to the output flange. Failure to observe the greasing specifications may lead to damage on the output flange Do not contaminate the thread ofthe output lange with grease. ‘+ Clean thread (1) of flange off adhesive residue. + Clean geating (2). + Grease gearing (2) Expendable materials Lubricating grease Optitemp HT 1LF 50 , 83230417754 Tube ‘+ Renew the seal, recessed nut (1) and the mounting clip (2) Parts: Seal, recessed nut and mounting ci. + Insert recessed nut (1) including gasket into collar insert ofthe flange nut. + Installthe mounting lip (2) + In order to avoid a humming noise of the drivetrain after reinstaling the propeller sha: itis essential to reassemble the three-hole flange (3) with the flexible disc (2) in the same position + Renew ZNS scrows and the selHlocking nuts (1). Parts: ZNS screws, selFlocking nuts ‘+ Position the scrows and nuts (arrows). + Tighten the screws, Front flexible disc to propeller shaft m2 Renew screws. Jointing torque 55m Comply with jointing torque and angle of rotation. ‘Angle ofrotation 90° Tightening via screw.Push the propeller shaft (1) in the direction of the arrow against the recessed nut (2) up to the limit position Manually screw on and tighten the recessed nut (2) onto the propeller shaft (1) by a minimum of two threads. Centre mount with TOP marking: ‘The centre mount (1) must be installed with the TOP marking at the top in the gearbox tunnel, Position centre mount. Position screws (1). Propeller shaft with a narrow universal joint: Using the special tool 2 464 898 and a suitable tool (2), secure the propeller shat (1) to the centre universal joint against twisting Propollor shaft with a broad universal joint: Secure the propeller shaft against twisting atthe centraluniversal joint Using a suitable tool (1).Damage to the flange nut, Failure to observe the installation specifications may lead to serious damage to the flange nut and the rear axle differential. Do not use the double hexagon flange nut as counter support. ‘Screwin the recessed nut within § minutes. ‘+ Screwin the recessed nut counter-clockwise, sé special tools 0 495 554 (39 5 070) and The recessed nut must be screwed in within 5 min Propeller shaft on the rear axle differential Insert nut Tightening 100/Nm torque direction of arrow with + After the propeller shaftis installed and the recessed nut is screwed in, strictly observe a hardening time of minimum 3 hours. Do not move or push the vehicle during this time! FS «Brace mounting bolts of flexible disc on nut and tighten by screw. >} JO 8120S car fexible disc to three-hole lange m2 Renew screws. Jointing torque 55m Jointing torque and angle of rotation must be observed without fai. Angle of rotation 90° Tightening via screw. ‘+ Secure the special angle of rotation too! 0.490 504 (00 9 120) with the ‘magnets to the vehicle underbody and serew it further depending on the angle of rotation + Tighten the screws (1). Centre mount to body Me Tightening 19Nm torque 19 — Install transmission cross member.T+ Instalthe transmission cross member (3). || + Insert screw (2) and tighten until hand-tiht + Tighton the screws (1) Transmission cross member to body we Renew screws Tightening torque + Tighten down serow (2). Transmission cross member to rubber mounts m2 Tightening torque ‘+ Loosen the tensioning strap (1) trom the transmission, transmission, + Version 1: Insert and install the rear underbody protection (1). Tighten screws (arrows) 2% & es oy Underbody protection Hexagon Tightening ‘screw torque + Version 2: Insert and installthe rear underbody protection (1) Tighten screws (arrows) Underbody protection Hexagon Tightening ‘screw torque 21 — Install the heat shields 19Nm 100Nm ‘+ Remove the special tools 0.495 496 (23 4 050) and 2219 012 from the 3Nm 3Nm‘+ Instal heat shield (1), ‘+ Tighten the nuts and bolts (arrows). He: to vehicle underbody Sorews and Tightening nuts torque + Installheat shield (1) + Tighten the nuts and bolts (arrows). Heat shield to vehicle underbody ‘Screws and Tightening ruts torque 22 Installing the complete exhaust system 3Nm 3Nm Component with heavy weight. | Danger of injury! Note component's contre of gravy. Support component using a jack Secure component against fang off the jac. Heavy component. Heavy components can lead to injury or damage. Remove and instal heavy components vith the aid of another person/other persons,, © ‘Swarf resulting from sawing or grinding components. Danger of injury! Conduct all work in appropriate personal protective equipment only, Wear safety goggles and protective gloves. ee SS Eee + Equipment specification 1 (ribbon clamp) (Open the weld seam (1) with a conventional tool. ‘+ Remove ribbon clamp (2) ‘+ Renew the (2) ribbon clamp. Parts: Ribbon cable clamp ‘+ Feedin and install the exhaust system (3) with a second person. + Renew nuts (2). Parts: Nuts ‘+ Tighten nuts (2). Rear silencer to body / bumper support MB Replace nuts. Tontening 19Nm jorgue + Connect connectors (1) and lock, ‘The connector (1) must engage auaibly. + Renew nut (1). Parts: Nut ‘+ Tighten the bolt (1) on the rear axle support. =, Exhaust system to rear axle carrier Nut Me Renewnut Tightening 19Nm torque + Renew nut (1) Parts: Nut B + Tighten nut (1) Front silencer / petrol particulate fter on transmission bracket Me Renewnut Tightening 19Nm torque‘+ Tighten the ribbon clamp (1). Exhaust system to catalytic converter Ribbon cable Renew flat band clip. Tightening 26.Nm clamp torque + Equipment specification 2 (V-clips) ¥ Renew V-band claro, Parts: V-band clamp ® Unscrew the nut (1) and remove the sealing ring (2). , + Bend all sheet metal tabs over with a suitable tool, except those in the C ) marked areas. ‘+ Mount the V-clp (1) on the seating ring (2) ‘+ Make sure that the V-clip (1) is positioned comectly on the sealing ing (2), ‘+ Ensure that the V-clp rests against the sh areas after mounting.‘+ Connect the exhaust systam (1) with the catalytic converter (2) and position it correctly (arrow). + Make sur that V-lp (1) ted conect '* Tighten down screw (2). Veetptocatayiccomvertey (elcid earee rl 23 Install the connecting supports on the tunnel Gp Oe Tightening 22m torque ‘+ Guide in and install connecting support (3) on the tunnel, + Tighten the screws (2). Connecting support to tunnel Max25 screw Tightening 20Nm torque Sorew Tightening 3Nm torque + Tighten screws (arrows). Connecting support to tunnel Max25 screw Tightening 20Nm torque Sorew Tightening 3Nm torque installed: Secure clamps (1). Insert special too! into fuel filer neck. ‘Special tool has two different diameters: for petrol and for diesel fuel. Slide the suction hose (1) of the extractorunit about 40 cm into the fuel filer neck. Fnecessary, sightly tun the suction hose. Filfuel from suction extractor unt [After completing the work and before starting the engine forthe fst time: Filthe fueltank by the fuel flerneck with a minimum of § lof fuel.Uverview or rigmening 1orques Fuel tank to body Used n stop 13 Nut Me: Renew nut. Fuel tank retaining strap to body Tightening torque 19Nm Used n stop 13 Ma serew Renew screws. Filing hose on fuel tank Tightening torque 19m Used n stop 18 Hose clamp Replace hose clamp, Tightening torque 4Nm Rear upper seat belt to bottom body Used stop 15 ‘Screw Renew serew. Tightening torque 42Nm Brake disc to front wheel hub Used nstop_17 Ma Renew screw, Brake disc to rear wheel hub Tightening torque 16Nm Used n stop 17 Tightening torque 16Nm Used n stop_17 Ma Renew screw. Wheel bolts Mia /swi7 ‘Screw in wheelbolts and evenly tighten crosswise by hand in orderto centre the wheel rim Tighten wheel bolts to the prescribed tightening torque with a calbrated torque wrench ina crosswise sequence Check allthe whee! botts in the same order or retighten to the prescribed tightening torque again Front flexible disc to propeller shaft Tightening torque ‘Check 140Nm 140Nm Used a stop 18 mie Renew screws. ‘Comply with jointing torque and angle of rotation, Tightening via screw. Propeller shaft on the rear axle differential Jointing torque ‘Angle of rotation 55Nm 90° Used n stop 18 Insert nut Rear flexible disc to three-hole flange Tightening torque 100 Nm Used n stop 18 m2 Renew screws, Jointing torque and angle of rotation must be ‘observed without fall Tightening via serew. Centre mount to body Jointing torque ‘Angle of rotation 55m 90° Used n stop 18 Ma ‘Transmission cross member to body Tightening torque 19Nm Used n stop 19 Ma Renew screws, Tightening torque 19Nm‘Transmission cross member to rubber mounts Used n stop 19 m2 Tightening torque 100 Nm Underbody protection Used n stop 20 Hexagon screw Tightening torque 3Nm Heat shield to vehicle underbody Used n stop 21 ‘Sorews and nuts Tightening torque 3Nm Rear silencer to body / bumper support Used n stop 22 Ma Replace nuts Exhaust system to rear axle carrier Tightening torque 19Nm Used n stop 22 Nut Ma: Renew nut Frontsil ncer | petrol particulate filter on transmission bracket Tightening torque 19m Used n stop 22 Ma Renewnut, Exhaust systom to catalytic convertor Tightening torque 19Nm Used n stop 22 Ribbon cable clamp Renew at band ci. Vclip to catalytic converter Tightening torque 26Nm Used n stop 22 \V-band clamp Renew V-band clamp. Connecting support to tunnel Tightening torque 22Nm Used n stop 23 ‘Max25 screw Sorew Overview of Special Tools 0.495 498 (23 4 050) Support Tightening torque Tightening torque 20Nm 3Nm Usedinsiep 619Common (universal gearbox holder) Suppor for removing and Usage instaling manual gearboxes and automatic, transmissions for BMW & RR. Included in the tool creer Storage beaion Indu Replaced by a situmoer 010706 (256) Consisting of m BM over Roplaced Pes Destnation Comocion ares by en naa (Foom mater ns 2 oseseto asa Sot 4 piacos) coated, canbe srdred ony via ciel Joint fvatal ol as 4 1 945547 (234 Commie toolset 234 0108300495 108) ssolteort2 — {Gose fare) Avatabie 2 esesete(as4 only an aconslete fo) ‘set 23 4 050 (83 300.495 480)- ao of 180712 bat CTansioning sap) 4 0495580234 fatale ony a6 os) Complete oo sot 24 050 (83 30 0.495 498) - ssotteorta Support (Fixture for foam insert) 5 0406018(234 fvalebe onan oss) conpble clas 23 4 050 (83 30 0.495 498) - as of 16.07.12.2.219 012 Hydraulic lifter Common Used instep 619 Usage For raising and lowering various vehicle components. Included in the tool ‘orwork Storage cation Replaced by Inconnection with ‘SiNumber (01 05 90 (207) 2.464 898 Open-end spanner Common instalation oft ec diferentil, The delivery speciation. Included in the tool ‘orwork Storage bation AT Replaced by senses Iq connection with ‘SitNumber (01 19 18 (579)0.495 584 (33 5 070) Extension 2344011 Too! Common Usage Included in the tool orwork Storage beation Replaced by Inconnection with ‘StNumber Consisting of BMW Order POS number 1 2495 592 (935 ont) Common Usage Included in the tool ‘orwork Storage beation Replaced by Inconnection with ‘StNumber Usedin step 718 Pultout extension for 33 § 040, 33 5 050, 33 5 060. Ais 01 21 06 (300) Replaced in 5 Designation Connection 1 with Extension (Extension (1 tem) discontinued, can only be ordered using complete tool Used a stop 17 Tool (whee! hub grinder) for cleaning the connection of the wheel im (wheel contact face) to the whee! hu. 08 08 12 (872)Replacement tools: 0.495 221 (36 1 323) Wheel stud 0.490 504 (00 9 120) Torque angle measuring dial ‘Common Used stop 18 For torsion angle adjustment of cyinder head bolts Usage {allengines) And reinforcement plate front axle support E46 Included in the tool ‘orwork Storage cation Ad Replaced by In connection with StNumber woos 0 Common vsseinatp 8 tae (Code 30) Code 39 available separately, (see EPC) under 36 18 1 181 259, Includedin the tool 9 ago sig orwork Storage location Replaced by In connection with ‘stNumber0.495 224 (36 1 326) Wheel stud ‘Common used instep 6 (Code 33) With centring bore avaiable separately, nee (see EPC) under 36 13 6 765 548 Incudedinthe too! 9 499518 Storage location Replaced by In connection with ‘stNumber ‘Common Used stop 8 (Code 34) With centring bore avaliable separately ae (see EPC) under 36 13 6 765 547 Included inthe too! 9 gop 518 Storage location Replaced by In-conneetion with skNumber ‘Common Used hstep 8 (Code 35) With centring bore avalable separately, mee (see EPC) under 36 13 6 762 340 Included nth 001 9 gop 518 Storage location Replaced by In connection with StNumber ‘Common Usedinstep 8 (Code 36) With centring bore avalable separately anal (see EPC) under 36 13 6 762.341 Included in the tool 9 gga 51g or work Storage location Replaced by In connection with ‘stNumber0.495 228 (36 1 331) Wheel stud ‘Common used instep 6 (Code 37) With centring bore avaiable separately nee (see EPC) under 36 13 6 762.342 Included inthe too! Inetudec 0492518 Storage location Replaced by In connection with ‘stNumber 0.495 229 (36 1 332) Wheel stud Common Used howe 8 (Code 38) With centring bore avaiable separately mal (see EPC) under 36 13 6 762 343 Incudedinthe 001 9 gaa gta Storage location Replaced by In connection with ‘StNumber Common Used step 8 (Code 40) With centring bore avaiable separately banat (see EPC) under36 13 6 762344 Included in the tool or work Storage location Replaced by In connection with 0492 518 ‘stNumber1612010 Removing and installing or replacing carbon canister PRELIMINARY WORK 1—Remove cover for carbon canister Som ‘+ Remove the cover (1).MAIN WORK 2. Removing the carbon canister (European version) ‘+ Unlock and pulloff the snap fasteners (1) + Loosen the nuts and screws (1) and remove the carbon canister (2) 3— Installing the carbon canister (European version) = = ‘+ Position carbon canister (2). + Fix and tighten nuts and screws (1). Carbon canister to body Renew screws /nuts. Tightening 8Nm torque + Fit and lock snap fasteners (1).POSTPROCESSES 4 Installing the carbon canister cover [ F ZY SS ‘+ Install the cover (1) Additional Information Overview of Tightening Torques Carbon canister to body Renew screws /nuts. Tightening torque Used instep 3 8Nm1612 200 Removing and installing/replacing the external fuel filter PRELIMINARY WORK 1—Removing the underbody panelling on the left-hand side ‘+ Unscrew all bolts and nuts (arrows). H| - Remove the underbody paneling (1) MAIN WORK 2.Remove the external fuel fier ‘Working on fuel system. Risk of fel Danger of explosion! + When working on the fuel system, make sure that the workbay is sufficiently ventilated, e.g. using extraction unit, + Tightly sealoff open lines and connections; collect any escaping fuel directly atthe point of ext, + No fire, sparks, open flames or smoking LS ed Collect and dispose of emerging fds, Observe country-specific waste disposal regulations. ‘+ Unlock and release fuel tne (1) Unlock and loosen fuellines (2). + Loosen nut (3) + Unlock the lock on the holder (4), ‘+ Guide out and remove holder (4) + Guide out and remove fuel fiter (5). 3 Install the external fue! fitorWorking on fuel system. Risk of firel Danger of explosion! ‘+ When working on the fuel system, make sure that the workbay is sufficiently ventilated, e.g. using extraction unit + Tightly sealoff open lines and connections; collect any escaping fuel drectly atthe point of exit + No fire, sparks, open flames or smoking Mcunen Somcnnud Collect and dispose of emerging fuids. Observe country-specific waste disposal regulations. + Insert and installthe new fuel fiter (5). + Instalthe holder (4) and secure it with the lock. + Tighten nut (3) Fuel fter on vehicle underbody M6 Tightening 6Nm torque AL + Connect and audibly lock the fueliines (2) TT + Connect and audibly lock the fueltines (1). POSTPROCESSES 4 Installing the underbody panelling on the sides on left Tightening 26Nm torque Tightening 2,6Nm torque Additional Information Overview of Tightening Torques Fuel fiter on vehicle underbody Usedinsep 3 M6 Tightening torque Nm Underbody panelling, side Usedinsep_4 Hexagon screw Tightening torque 2,6Nm Plastic nut Tightening torque 26m16 13 522 Removing and installing/replacing temperature sensor for Natural Vacuum Leak Detecti (NVLD) (after vehicle diagnosis) PRELIMINARY WORK 1—Removing seat bench ‘+ Disengage the seat bench (1) in area (2) in an upward direction. + Feed out the seat belt buckle (3) from the seat bench, + Pull the seat bench (1) further forward. + Release screw (2) onthe end iting and guide out be (3) Note: there isa belt lock onthe bet the serew on the end fiting must not be released + Htnecessary, dsconnect ihe present plug connections + Lift the seat bench (1) out of the vehicle. ‘+ Expand the floor trims in the area (1) in drection of arrow, ‘+ Tum the sealing cap (1) in the direction of arrow (anticlockwise)MAIN WORK '3~Remove temperature sensor + Disconnect plug connection (1). + Carefully press the tab (1) in the direction of the arrow. + Remove the temperature sensor (2) towards the top. ‘+ Insort the temperature sensor (1) from the top. + Make sure the retaining tab (2) is correctly engaged with the latch mechanism. ‘+ Connect the plug connection (1). POSTPROCESSES 5 Closing the service opening‘+ Renew the sealing cap of the floor panel. Parts: Sealing cap of the floor panel ‘There is a risk of leakage ifthe sealing cap of he floor panelis reused. + Coat gasket in area (1) using Carbaflo KSP 105 lubricant (see Electronic Parts Catalogue). + Engage sealing cap (1) in direction of arrow up to the limit position. Mark (2) must point forwards in the direction of travel, + Sealcarpet in area (1) ‘+ Li the seat bench (1) into the vehicle. *+ Insert the seat belt (3). ‘+ Renewthe screw (2). Parts: Screw + Tighten down screw (2) Rear upper seat belt to bottom body Screw Ronow screw. Tightening 42Nm torque ‘+ Connect available connectors. ‘+ Insert seat bench (1). + Thread seat belt buckles (3) into the seat bench, | + Engage the seat bench (1) in the area (2)Additional Information Ove w of Tightening Torques Rear upper seat belt to bottom body used atop 6 ‘Screw Renew screw. Tightening torque 42Nm16 14500 Removing and installing or replacing control unit for electric fuel pump Gone [By Etectostate discharge, Damage to or destruction of electrical components. Leave electrical components in original packaging untljust before they are installed, Use the original packaging ‘only for any return shipments. Always package removed components straight away. Read and comply with userinformation on using the associated special ool 12 7 060. ‘Oniy touch the housings of electrical components. Do not touch pins or multipin connectors directly. Wear electrically conductive clothing and antistatic shoes (wth ESD symbol). For additional information see: 61 35 Information on electrostatic discharge (ESD) protection. PRELIMINARY WORK MAIN WORK 11—Remove the control unit for the fuel pump control electronics ‘+ Expose floor trim in the area (1) ‘+ Disconnect plug connection (1). + Release plastic nuts (2) and remove control unit (3). 2 Install the control unit for the fuel pump control electronics+ Instal the control unt for the fuel pump control electronics (3) ‘+ Renew the plastic nuts (2). Parts: Plastic nuts. Position and tighten the plastic nuts (2) Control unit for electrical fuel pump control on body Renew plastic nut, Tontening 4Nm torque + Connect connector (1). + Close the floor trims in the area (1), POSTPROCESSES '3—Putting fuel pump control electronics into operation + Connect diagnosis and information system, + Perform fuel pump control electronics start-up, Additional Information Overview of Tighter 9 Torques Control unit fr electrical fuel pump control on body Used sep 2 Renew plastic nut Tightening torque 4aNm1614090 Removing and installing/replacing delivery unit PRELIMINARY WORK 1—Drawing off the fuel tank Contact with hazardous fluids. Hazardous to health! + Note and folow safety information on containers. + Conduct all work in appropriate personal protective equipment only. Working on fuel system, Risk of fil Dangor of explosion! ‘+ When working on the fuel system, make sure that the workbay is sufficiently ventilated, e.g. using extraction unt. + Tightly sealoff open lines and connections: collect any escaping fuel drectly at the point of exit + No fire, sparks, open flames or smoking pen tue! filer cap. Insert special too! into fuel filer neck. Tho special too! has two diferent diameters for petrol and diesel vehicles. Push the suction hose (1) of the extractor unt through the specialtool and into the fuel ler neck. necessary, slightly tum the suction hose. For the extractor unt: see BMW service workshop equipment, ‘The insertion length of the suction hose is 135 em. Start engine and allow to run, so that the electric fuel pump is running. ‘This will ensure that the fuel is pumped by the suction jet pump from the leftchand side of the fuel tank to the right hand-side. Draw off fuel with the extractor unit as far as possible. In the process, track the drawing off of the fuel on the fuel gauge inthe instrument cluster 2.—Removing seat bench Disengage the seat bench (1) in area (2) in an upward direction, Feed out the seat belt buckle (3) from the seat bench,‘+ Pullthe seat bench (1) furthar forward. ‘+ Release screw (2) on the end fiting and guide out belt (3). Note: Ifthere is a belt lock on the belt, the screw on the end fiting must not be released, + Ifnecessary, disconnect the present plug connections. + Lif the seat bench (1) out of he vehicle. '3~ Opening the locking ring (vehicle without auxiliary heating) Working on fuel system. Risk of fire! Danger of explosion! ‘+ When working on the fuel system, make sure that the workbay is sufficiently ventilated, e.g. using extraction uni. '+ Tightly sealoff open tines and connections; collect any escaping fuel directly atthe point of exit. + No fre, sparks, open lames or smoking, TECHNICAL INFORMATION Collect and dispose of emerging fhids. Observe countr posal regulations. ‘+ Expand the floor trims in the area (1) in direction of arrow. + Tum the sealing cap (1) in the direction of arrow (anticlockwise).‘+ Unlock the lacking tab (1) inthe direction of the arrow. + Operate the tab (2)and pullof! the connector housing, + Unlock and pullotf snap fastener (1) + Equipment specification with optional equipment 1AK (external fuel filter). Unlock and pulloff the snap fasteners (1). necessary, unlock and disconnect the snap fastener (2) forthe auxiliary heater, + Fit the special tool 2 452 189 or (1) on the locking ring (2), B+ Connect the special oo! 495 854 (33 5 070) to a 12 inch rever ratchet head (3) and ft on the special ool2 452 189, rs (2.452 189) + Release locking ring (2) in counterclockwise direction o/s MAIN WORK 4—Remove delivery unit+ Litftange lid (1) indirection of arrow + Disconnect plug connection (1). ‘+ Remove cable holder (2) and sever cable tie (3) ‘+ Unlock the tab (1) and remove the slosh side (2) towards the top. ‘+ Unlock and pull off snap fastener (1). + Unlock lock (2) n dtection of arow tom the top. ‘+ Slightly push delivery unit (3) in direction of arrow and feed out to the top. + Feed in delivery unit (1) in direction of arrow from the top and lock. Ensure the delivery unitis properly locked in the mounting! *+ Lock the lock (2) in direction of arrow to the bottom. + Posttion snap fastener (3) and lock.‘+ Insort splash wall(1) trom the top and lock tab (2) ‘+ Connect the plug connection (1). ‘+ Renew cable holder (2) and cable connector (3) Parts: Cable holder, cable connector ‘Attach cable to the brackets . ‘+ Renew sealing ring (1). Parts: Sealing ring ‘+ Mount lange Id (1) in direction of arrow. POSTPROCESSES 6 ~ Closing locking ring (vehicles without stationary heating system)Working on fuel system. Risk of fire! Danger of explosion! ‘When working onthe fuel system, make sure that the workbay is suffiienty ventlated, e.g. using extraction unt “+ Titty sealottopen nas and connections; collect any escaping fuel drecty atthe point of ext 1 Le parks, open flames or smoking J Mcunen Somcnnud Collect and cispose of emerging fuids. Observe country-specific waste disposal regulations. ‘TECHNICAL INFORMATION Allnew delivery units are delivered with the stationary heating system in the equipment specification. For these vehicles, the connection on the flange lid must be closed with a locking coupling. Locking coupling must be ordered separately, see Electronic Parts Catalogue. ‘+ Fit the special tool 2.452 189 or (1) on the locking ring (2), + Connect the special too] 0 495 554 (33 5 070) to a 1/2 inch reversible ratchet head (8) and fon tho special too!2 452 169 ‘+ Tighten locking ring (2) in clockwise direction, + Make sure tha the locking rng to the fuel tankis engaged conecty + Position snap fastener (1) and lock. ‘+ Connect the plug connection (2) ‘+ Fitthe plug connection and atch ft. + Lock retaining tab (1) in the direction of the arow.‘+ Renew the sealing cap of the floor panel. Parts: Sealing cap of the floor panel ‘There is a risk of leakage ifthe sealing cap of he floor panelis reused. + Coat gasket in area (1) using Carbatlo KSP 105 lubricant (see Electronic Parts Catalogue). + Latch sealing cap (1) up to the imit position inthe direction of the arrow. “Mark (2) must point to the front in the direction of travel. + Lock the carpet in area (1). ‘+ Li the seat bench (1) into the vehicle. *+ Insert the seat belt (3). ‘+ Renewthe screw (2). Parts: Screw + Tighten down screw (2) Rear upper seat bet to bottom body Screw Ronow screw. Tightening 42Nm torque ‘+ Connect available connectors. ‘+ Insert seat bench (1). + Thread seat belt buckles (3) into the seat bench, | + Engage the seat bench (1) in the area (2)2 = rung tne rue! tanx 2 em Insert special too! into fue ler neck ap i. (Gas ~ ie Se ‘Special tool has two different diameters: for petrol and for diesel fue. Slide the suction hose (1) of the extractor unit about 40 cm into the fuel filer neck. F necessary, sightly turn the suction hose. » Filfuel om suction extractor unt. y ‘After completing the work and before starting the engine forthe frst time Filthe fuel tank by the fuel flor neck with a minimum of § lof fue SA Additional Information Overview of Tightening Torques Rear upper seat belt to bottom body Used in step_7 Screw Renew screw, Tightening torque 42Nm Overview of Special Tools 2.482 189 Wrench Common Used n stop 36 — ‘Tank unlocking key large as replacement for 0496321; ‘SWZ applies to ALL derivatives up to mid-year 2017 Included in the tool ‘orwork Storage beatin C5 Roplaced by Inconnection with Geonoeres ShNumber 01 03 17 (478) 0.495 554 (33 5 070) Extension Common Used n stop 36 Usage Pulhout extension or 33 5 040, 39 5 050, 33 5 060, Included in the tool ‘or work Storage bation A18 Replaced by Inconnection vith y stNumber 0121 06 (200) Consisting of in Pos BMW Order RERIRCEG op sionation Connection y wath Extension (Extension (1 item) Tepe dscontinved, can only be ordered using complete tool1614065 Removing and installing/replacing dust filter for Natural Vacuum Leak Detection (NVLD) PRELIMINARY WORK 11—Removing the rear right wheel » Removing the wheel + Invehicles with M Carbon ‘ceramic brake: The wheel assembly jack must be used to remove the wheel (see workshop equipment) This process is intended to prevent damage to the brake disc. I several wheels are removed simultaneously: Use a piece of chak to rmatk on each tyre the axle and side on which the corresponding wheel is fited + Release the wheel bolts (arrows) crosswise and remove the wheel. ‘+ To release and tighten whee! bolts with a security code: Use a suitable adapter from the toolset . 2— Removing rear wheel arch cover ocd ‘To provide a better overview: Schematic diagram with partially hidden components,+ Loosen screws (1). + Loosen nuts (2). + Guide the wheelarch cover (3) out. MAIN WORK ‘+ Unlock and disconnect snap fastener (1). + Detach the holders (2) and remove dust fter(3) with line. *+ Install the dust fiter (3) with line in the holders (2) ‘+ Position snap fastener (1) and lock. POSTPROCESSES 5—Removing the rear wheel arch cover eos To provide ‘overview: Schematic diagram with partially hid+ Guide the wheelarch cover (3) in + Tighten the screws (1) + Tighton nuts (2) Maca The contact surface between the brake disc and the whee! rim must be clean and free trom oil and grease. There is otherwise a risk of the wheel becoming loose at a latertime. ‘+ Remove dit, grease residues and corrosion from the contact surface with a dill and the special tool2 344 011, Do not operate special ool 2344 011 with an impact screwdriver. ‘+ Degrease the contact surfaces with the universal cleaner (see BMW Group Parts). ‘+ In the event of grease residue in he area ofthe whee! bolt holes, remove and clean the brake disc. ‘+ Remove din, grease residues and corrosion from the contact surface with adil and the special ool2 344 011, Do not operate special tool 2 344 011 with an impact screwdriver. + Degrease the contact surfaces with the universal cleaner (see BMW. Group Parts) Check that the mounting bot (1) for the brake discis securely seated. The mounting bol (1) for the brake disc may not protrude under any circumstances on the contact surface (2) between the brake disc and the ‘wheel im, Brake disc to front wheel hub MB Renew serew. Tightening 16Nm torque Brake disc to rear wheel hub Me Renew screw. Tightening 16Nm torque© ay . ‘+ Thinly grease the wheel centring (1) in the whee! rm. Expendable materials Brake block paste *TU=Trade Unit. TU numbers ‘cannot be ordered! For invoici purposes only. ing 39, 89192158851 Bag 1009, sa1921s8852 Tube 59, 193290140283 w ‘+ Uightly grease the front and rear whee! hubs in this area (1) to protect from corrosion, Expendable materials Brake block paste *TU=Trade Unit. TU numbers ‘cannot be ordered! For invoicing purposes only. 39, Bag 1003, Tube 5a, u 23192158851 93192158852 183290140283 Invehicles with M Carbon ‘ceramic brake: The whee! assembly jack must be used to installthe wheel (see ‘workshop equipment. This process is intended to prevent damage to the brake disc.Ecc iene Neveruse impact screwdrivers or electric screwdrivers to screwin and tighten the wheel bolts, |The wheel rim must rest unitormly against the brake dis. 1 In the case of nonoriginal BMW wheelbottsivhee! ims, tt may be necessary to retighten the wheel bolls on account of setting properties (refero the documentation from the manufacturer), Do not apply ollto new whee! bolts. ‘+ Renew corroded whee! bolts Parts: Wheel bolts + Clean the wheel bots + Check wheel bolts and threads for damage, renew the wheel! bolts if necessary. ‘+ Join and tighten the whee! bolts (arrows). Wheel bolts MI4/SW17 Screwinwheelbots and Tightening 140 .Nm evenly tighten crosswise by torque hand in orderto centre the wheel im, Tighten whee! bolts to the prescribed tightening torque with a calibrated torque wrench inacrosswise Check Pea sequence. Checkall the whee! bots in the same orderor retighten to the prescribed tightening torque again Additional Information Overview of Tightening Torques Brake disc to front wheel hub: Usedinsep 6 MB Renew screw, Tiohtening torque 16Nm Brake disc to rear wheel hub sed inst 6 Ma Renew screw. Tightening torque 16Nm Wheel bolts Usedinsiop 6 Mia/swi7 Screw in wheel bolts and evenly tighten Tightening torque, 4401Nm crosswise by hand in orderto centre the wheel rim Tighten whee! bolts to the prescribed tightening torque with a calbrated torque wrench ina crosswise sequence. Check 140Nm Check allthe wheel botts in the same order or retighten to the prescribed tightening torque again.Ove w of Special Tools 2344011 Too! Common sed stop 6 Tool (whee! hub grinder) for cleaning the connection Usage ofthe whee im (wheel contact face) to the whee! hue. Included in the tool ‘orwork Storage location Replaced by In connection with StNumber 08 08 12 (872) Replacement tools: 0.495 221 (36 1 323) Wheel stud ‘Common Used instep 1 (Code 30) Code 39 avaliable separately, (see EPC) eee under 36 13 1 181 259, Incudodin tho too! 9 gop 518 Storage location Replaced by In connection with ‘StNumber ‘Common Used step 1 (Code 33) With centring bore avaliable separately, bane (see EPC) under 36 13.6 765 546 Included nth t001 9 gop 518 Storage location Replaced by In connection with ‘StNumber ‘Common Used instep 1 (Code 34) With centring bore avalable separately ae (see EPC) under 36 13 6 765 547 Included in the too! 9 ago sig orwork Storage location Replaced by In connection with ‘StNumber0.495 226 (36 1 328) Wheel stud ‘Common sed instep 1 (Code 35) With contring bore avaiable separately, Usage (see EPC) under 36 13 6 762 340 Included inthe too! reuse 0492518 Storage location Replaced by In connection with ‘stNumber 0.495 227 (36 1 329) Wheel stud ‘Common Used nee 1 (Code 36) With centring bore avaiable separately mal (see EPC) under 36 136 762.341 Included in the too! 9 gga sig or work Storage location Replaced by In connection with ‘stNumber ‘Common sed natag 1 (Code 37) With centring bore avaiable separately banat (see EPC) under 36 13 6 762342 Included in the tool orwork Storage location Replaced by In connection with 0492518 ‘StNumber ‘Common sed natap 1 (Code 38) With centring bore avaiable separately ane (soe EPC) under 36 13 6 762343 Included in the tool orwork Storage location 0492518 Replaced by In connection with ‘StNumber(0.495 230 (36 1 333) Wheel stud Common Usedinstp 1 (Code 40) With contring bore available separately bees (see EPC) under 36 136 762.344 Included inthe too! Inetudec 0492 518 Storage location Replaced by In connection with woe1s | SkNumber6400 equipment) Information on using cleaning agent/paints (personal protection a! Use of cleaning agents/paints not compliant with instructions ean ‘cause serious injuries or bus! 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 agentsipaints from high temperatures and direct sunight, + Always keep an eye douche on hand, change the water regularly (once a month). Important! (Observe following instructions before use: + Manufacturer’ instructions (on container/packaging) + Hazard wamings (on containeripackaging) + Manufacturers instructions on package insert + Materia safety data sheet of manufacturer + Product information in EPC + National market regulations Important! Observe following instructions during use: + Do not eat, drink or smoke while working with these products, + Avoid direct contact wth 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 agentipaint. + After finishing work, wash your hands and apply protective skin cream Important! Follow hazard wamings and wear personal protection equipment!First Aid + Hf product comes in contact with eyes, immediately flush with running water for about 10- 15 minutes. Seek the advice of eye specialist, ‘+ Inthe event of skin contact and where applicable an allergic skin reaction, clean the affected aroas immediately with soap and water and then apply siicone-free skin cream. Seek advice of physician. + an adhesive product is swallowed, rinse mouthiparts of mouth thoroughly with running water. Drink 1-2 glasses of water, Do not induce vomiting. Consult a doctor. + Atter inhaling vapours ensure ample supply of fresh air. Keep calm, koop respiratory tracks clear and call doctor. Recycling: Dispose of cleaning agents/paints in a professional manner! (Observe nationa/country-specific disposal regulations.17 00 039 Bleed the cooling system and check it for watertightness with the special tool _eeeeeE———eEeEeEeEeEeEeEeEe Hot surfaces, Risk of burning! + Perform al work only on components that have cooled down, PRELIMINARY WORK 1 Fllthe high-temperature cooling system withthe vacuum filer device Vacuum filer device CR Se ais ‘Vacuum fier deve connected to the coolan expansion tank 1 Vacuum filer device with pressure gauge and shutof valves 2 Filing hose 3 Fluld tank with coolant 4 Venturi nozzle '5 Compressed air connection (maximum of 6 bar) 6 Outgoing hose ead out-going hose into a collecting vessef) Prerequisite ‘Te coolant expansion tan forthe cooling system must be empty. The Mud tank ofthe vacuum llr device must have a suficent quantity of premixed coolant, 1110 21 mare than the specified capacty or the vehicle. The fui tank ofthe vacuum fle device must be positioned altho same height as the coolant expansion tank. The compressed air connection must have a pressure of 6 bar. Ignition is switched of oa Folownotes fo apa work on th cootng systom. For adctonaliniormaton see: Nan group 17 1700... Notes for working on the cooling sya Litedong fil f coolant! Do net reuse used coolant. When replacing and removing components whch ely onthe corrosion protection esc ofthe coolant essential to change the coolant. ‘The cooing aystom must therefore bo emptiod and ellos. Inthe aso of ethor moval workinvoting the draining of pst quantities of cootan, tho coolant lovelimust be topped up with new cook i oa Nexng aferent coolant not permite. i oa Filing without ne vacuum er dove (watering canting) isnot permite, Ner-complance wil esul In danger of component damage andlor engine damage. Filing spacticaion absolutely mustbe acheredo. ‘The operation othe vehicle isnot permitted unless the fling procedure has been completed, Otherwise, funcional miaions (degradation) anior overheating may occur ‘Abloating procedures raquted ator aparthas boon exchanged inthe cooling system andr ato rofling the cooing system. ake sure thatthe igrton (torminal 18) is swichod off porto creating the vacuum wih tho vacuum flor davis, » Observe the coolant type Coolant nthe vacuum filer davice container on ‘aConimt Hz MNSielw16 (Choose the ovect enon for ing ‘Avehice must be filed wth the coolant with which t's dolvered ox works 1. 648 Blue) Gta must not be maxed win he BCoolat othe G30 MINI deseltueIW 16, 2.18 coolant (blues used ony forthe Ia heater crcut 8 coolant must rot be fled nthe other coolant ckcuts or mixed withthe other coolants ‘3. HT12 (Pink) HT12 must not be mixed wah the coolant orthe G30 MINI diesel tel W18, 4. HT12 Greon) #12 must rot be mitod wth the coolant or the G30 MINI disso uel 6 '5. 630 Pink) nust be used ony forthe MINI dasel fuel W16. G30 must not be ile nthe other coolant ctcults or mixed wth the other cootants.Eee Damage tothe engine. ‘The use ofan incorrect coolant may lead to corrosion or gelling inthe engine, “+ Use only approved coolants forthe spectc venice. "+ Filthe vehi only wth the coolant wth whch & was delivered ox works. "+ Noconlycompattle coolants. The colour does not alow any assessment abou the compat of coolants 1 [Sebo tie crete ony by ear te pain J + Seloct a suitable adapter (¥) rom the set of special tools 0404 417 (17 0100 Tyee Engine Adaptor) fom 170 100, jacana fase 508 88 Wor *+ The id tank ofthe vacuum filer doviee must b of coolant forthe vanile. Capacity of hightemperature coolant circuit G20 sd 1 2Imore than the spectod eapacty 12488200 184682001 eal Expendable materials: Technically sutable artéreszs and consion nhibitor + Connect the selected acapter(¥) tothe coolant exoansion tank + Connect vacuum flor dovie to conpection (x) ofthe adapter. ‘+ Check whether shutoff valves (A) and (8) ofthe vacuum lor dovie (1) are closes. + Connect andlock connection (Xo the coolant expansion tank + Connect Ventu nozzle (1) othe vacuum lr devies (2). as ‘ (00) the connection on the coolant expansion tank. [ @ FO | ua “a (n)s the connection on ine coolant expansion tank+ Open shut-of valve (8). ‘he venturinozzle produces & fow nose. + Open shutot vate (A) unt th + Close shutot valve (A) again >The ling nose (1) has now’ uel fing hose (1 is ul Wehout bubbles, sanded, ‘+ Chock he coolenthoses for porosity and renew porous coolant hoses as roquted. SSE ‘The coolantnoses contract dueng vacuum buld-p, “+ ‘ter having astabished a vacuum inthe coolant cout of between-0,7 to 0.95 bar (autlion approximately 2 min), close the shutof valve (8) “+ Check wrethar the snuto valves (A) and (8) ae closed. + Disconnect the Vartur nozzle (1) ure the vacuum nthe coolant ccut is mabainad for at least 20 seconds, Result > Vacuum sop. ropa iad stat tho ting procedure trom th begining.‘+ Make sure the vacuum nthe coolant eleut s malnained forat least 30 seconds, Test vacuum Result > Vacuum remains constant Measure + Continue wth fling, + Koop shut valve (8) closed during the fig procoss. + To the cooling system, open the shutot valve (A) tothe fis tank ofthe vacuum fer device + Stop the fling procedure when the noecle in the prossure massurng device ison O bao longer drops, ltnecessay, reduce remaining vacuum. In order do so, open shutof valve (8) ‘+ Remove the vacuum er device wih the adapter tom the hightemperature coolant expansion tank a, + Topup ne coolant tovelin the high temperature coolant expansion tank 1) tothe wer edge ofthe {e0otnt Mer neck (2) nthe high emperature coolant expans on tank). ‘ato fling the cooling system wth the vacuum iter deve, also run the cootng systom bleedng routine, — max oan MAIN WORK. 2 Bleed the high-temperature coolant circuit oa Leong filo coolant! Do not reuse used coolant, |Wihon replacing and omoving components which aly onthe corrosion protection efoct ofthe coolants essential to change the coolant. ‘The cooing aystem must therefore be emptied and reflod. Inthe case of ether removal workinvaWing the draining of pat quantities of coolant, the coolant vel must be topped up with new coolant.Fang without ne vacuum fer dove (natoing ca ing) snot permite | Non-comlance wrest in cangerafcomporent damage andor engre damage. 1 Fang speceaton absolutly must bo achoredo “The operation ofthe vohicl is not permitted unless the fling procedure has been completed. Otherwise, funciona mations (degradation) andlor overheating may occu. ‘Ableecng procedure required aera parthas been exchanged nthe cooling system andr ate reling the coolng system. Scan Before staring tha automatic cooling system beading routine, make sure that allcoolant circuits ae filed. tne cooling systam bleeding roulina is started while one ofthe coolant ercul is ply, there sa isk of damage othe elctfe coolant pump when running i ry “Make sure that terminal 15 isnot disconnected fo the bleeding procedure. Switch on lbw-boam heasighs and hazard wari lights. tho bbwrboamhoadignts and nazaré watning Ils ave rot swchod an, tho gniton terminal 15) wll such of automatealy ator conan por of lime and nterup the Bleeding procedure, cay ‘The electrical fans actvated during te ene cooling system Esedng rout The ating experience switch must not be et tothe ECO PRO ewkteh positon, + Open the blasdor sewn the coolant expansion tank forthe hightomperatue coolant crcut and fobse fagan ater approx 10's. ‘Youcan close the bleder screw priortoexpiy ofthe 10 s once coolant escapes. ‘Adustthe coolant levelinth hightemperature coolant expansion tank 1) to the lower age (2) the coolant ler neck of he the high temperature coolant expansion tank (1) + Chose sealing cap on tho coolant expansion tank of ho high-temperature cooling ckeut. “+ Make sure the bonnet fe closed, + Make sure thatthe wheots touch the ground + ngage the parking brake. Do not engage any gear in manuabshit gearbox, and engage the gearto “P” of N automatic transmission, Connect baltory charger. ‘Sileh on he ignion and make sure tha it mains switched on (or example, activate te lowe beam eadight and ne hazard warning Nght at the same time) the bw-boam headlight and the azar warring Ight ae net svtchod on, the ignition (terminal 15) wilswich off automatealy after some time ang iterpts he bleeding procedure Check that th devingexperence conttolisnetin the "ECO-PRO swich poston, [Adjust the heating te maximum tomporature and adjust the blower to the lowest stage Hold the accelerator pedal down othe Init postin for atleast 108 and do no kek the brake peda Startengine. Starthe cootng system sleeding routine, pay attention o the display on the instrument cluster (KOMBI). (Service tunction stares") ‘he engine speed (up to 3500 rpm) andthe acuatrs inthe cooling system are activated automatically for 11 mutes according to a coolng system bleecrg routine. ‘ho ongine spood drops to tho spot + Observe the dpa n:he instrument cluster {KOMB). lithe sonvze urctionisintemupted, the cooling system bleeding routine mustbe repeated + Such of engin + Allow the coolant temperatura to cooldown to <50%C,+ Loosen seatng cap (1). ‘TECHNICAL INFORMATION _Ater the cooling system blading routine the eocng systems topped up above the maximum mak. ‘Overing the coating system serves to balance the remaining an the cootng system, ‘The narmaliling kvsl ofthe coolants reached whip cving + Adjust tho fling bvalin the coolant expansion tank (2) ofthe hightemperature coolant cout to 200 ml over tne maximum mark). + Close seatng cap (1). f « ciose me seating cap (1) untithe arows ar tush. POSTPROCESSES '3~ Check the high-temperature cooling system for watertghtness Hot surfaces. Risk of burning! + Pertormallwork only on componeris that have cooled down. + Loosen seating cap (1).+ Attach the special tool 0404 £18 (170 104 with special tools 9.424439 (17 0102) and ‘094 642 (17.0113) Rom the set of special tools 094 £17 (570 100) ‘+ Bull up oxcoss prossure and wa for approximatoly 2 minutes Opening pressure of sealing cap /tet pressure of high-temperature coolant citcult cooling system Pressure rellet valve opens when the pressure min. 14bar ‘excoads the ambient pressure, Ect changeover vale must opon at latest max. 1 bar ‘when the pressure is lower than the arent pressure. “Test pressure fo cooling system (gauge 15ber pressure) ‘TECHNICAL INFORMATION Ifthe described test stop isnot completed successfully: repeat test stop twice. Only replace the sealing cap after three tests with an incorrect opening pressure \When civng at high ambient temperatures, the design may cause the pressure rele valve in the sealing canto open sight and ao escape together wth dissolved coolant. Ths coolant vapour condenses an the sufaco ofthe coolant expansion tank and leaves races of coolant ‘ahen the vente has cooled down. These traces of clant do nat Pete what the sealng {apis dotecive or nat ng cap (1) on special tool 404 643 (170 114) tomthe set of specialtook pane i717 0100) ‘+ Bull up the pressure wih speciltools 0404 418 1700101) and0.49¢ 410 17 0102) tomthe set of specialtool 0404 417 (17 0 100) ‘+ Observe onthe pressure measuring device when the opening pressure has bean reached. Opening pressure of sealing cap /tet pressure of high-temperature coolant circuit cating system Pressure riot valve opens when the pressure rin, 14 bar ‘exceeds the ambient pressure Ect changoover valve must opon at test max. 01 ar ‘wher the prossure is lower than the arent pressure. “Test pressure for coclng system (gauge 15bar Additional information Overview of Special Tools0.496.617 (170100) Testor Common Usage radar cap. Included tthe toot or work Storage bation Ihave! Replaced by In connection wth siNumber 010702 (684 Consisting of Pos BMW Oniernumber Replaced by 5 0.496 422(170 105) 10 0494427 (170111) 10494418 (170101) 2 0.496.419(170 102) 30498 420(170 108) 4 0408 421 (170 108) 5 0498-425(170 106) 7 0.496.426 (170107) 8 0498-425 (170 108) 8 0498-428 (170 109) 11 0.498 420 (170 112) 12 0494642 (170113) 13 0494649 (170114) 140496 889 (170115) Ussciene 13 For checking engine cooing systam on watorighiness. For chacking Designation Th Connection wih ‘Adapter For radiator cap (sawtooth threac) ‘Adaptor Forraditor cap ASSIW1, SOM adapter replaced 170052 Pump Hose (hose wn quek-olease couning) ‘Adapter Forradator cap (normal thread) ‘Adaptor Forradiatoreap (normal tread) ‘Adapter Forradator cap (sawtooth thread) ‘Adapter Forraditorcap R50 /W10 ‘Adaptor Forradatoreap ASO /Wi0 ‘Adapter Forraditor connection REM, FSON17 adapter coresponds to rroost case ‘Adapter Forraditor cap Model series: E60, 51, £83, £54 Sino, 10803 (688) ‘Adapter For adator cap Model sorios: £50, E61, E63, E04 Sino. 108 03 (268) ‘Adapter For radiator cap Model series: N12,0.494.418 (170101) Pump Benmore 8 nace hehsesin te tolorvane 0484417 ‘Storage bcaion Replacedoy Incarnation wth sinunter 0.496.419 (170102) Hose Common wredinene 8 Usage: (hose with qui rolease couping) Includaginthe toolorwork 0 404 417 Storage eeation Replaced by In connection wth stNumber 0-494 642(170113) Adaptor Common veedinewe 8 Usege. Forvadiator cap Model series: E60, E51, £63, £64 SIno.=1 0803 (088) Inctudedinthetoolorwork 0498 417 Storage eeation Replaced by In connection wth stNumber0.496.643 (17 014) Adaptor Common vectinaee 2 Usage Forvadiator cap Model sores’ E60, E61, E69, E64 SIno.1 0803 (288) Included inthe toolorwork 0404 417 Storage loeation Replaced by In connection wth stNumber Overview Technical Data pening pressure of sealing cap /tet pressure of hightemperature coolant eicult cooling system vectineee 8 Pressure ralit valve opens when the prossure exceeds the ambient, vin 1Abar pressure, Elect changeover vale must open t ltest when the pressures max. 0.1 bar ‘ower than the ambient pressure. Test pressure for coolng system (gauge pressure) 15bar Capacity of high tomperature coolant circuit G20 tecsnae 1 '34982001184882001 981 Expendable mattals: Technically sutabe antitesze and corosion itor Links: Repair instructions Used instop 1700 .. Notes for woréng on cooing ystom. 1 Operating materials Used instep Main group 17 117.00 040 Bleed the cooling system and check it for watertightness with the special tool _eeeeeE———eEeEeEeEeEeEeEeEe Hot surfaces, Risk of burning! + Perform al work only on components that have cooled down, PRELIMINARY WORK ‘1 Filing the low-temperature cooling system with the vacuum flr device Vacuum filer device Fooaonersoneteti te crttcmeerine 1 Vasu evn ith rns go shea 2 tg hone 2 Faint cost 1 Menten $ eamgesedcomesn fmm Sh 6 outgons hor fendoutgog here scotctng ese} Prerequisite ‘Te coolant expansion tan forthe cooling system must be empty. The Mud tank ofthe vacuum llr device must have a suficent quantity of premixed coolant, 1110 21 mare than the specified capacty or the vehicle. The fui tank ofthe vacuum fle device must be positioned altho same height as the coolant expansion tank. The compressed air connection must have a pressure of 6 bar. Ignition is switched of oa Folownotes fo apa work on th cootng systom. For adctonaliniormaton see: Nan group 17 1700... Notes for working on the cooling sya Litedong fil f coolant! Do net reuse used coolant. When replacing and removing components whch ely onthe corrosion protection esc ofthe coolant essential to change the coolant. ‘The cooing aystom must therefore bo emptiod and ellos. Inthe aso of ethor moval workinvoting the draining of pst quantities of cootan, tho coolant lovelimust be topped up with new cook i oa Nexng aferent coolant not permite. i oa Filing without ne vacuum er dove (watering canting) isnot permite, Ner-complance wil esul In danger of component damage andlor engine damage. Filing spacticaion absolutely mustbe acheredo. ‘The operation othe vehicle isnot permitted unless the fling procedure has been completed, Otherwise, funcional miaions (degradation) anior overheating may occur ‘Abloating procedures raquted ator aparthas boon exchanged inthe cooling system andr ato rofling the cooing system. ake sure thatthe igrton (torminal 18) is swichod off porto creating the vacuum wih tho vacuum flor davis, » Observe the coolant type Coolant nthe vacuum filer davice container on ‘aConimt Hz MNSielw16 (Choose the ovect enon for ing ‘Avehice must be filed wth the coolant with which t's dolvered ox works 1. 648 Blue) Gta must not be maxed win he BCoolat othe G30 MINI deseltueIW 16, 2.18 coolant (blues used ony forthe Ia heater crcut 8 coolant must rot be fled nthe other coolant ckcuts or mixed withthe other coolants ‘3. HT12 (Pink) HT12 must not be mixed wah the coolant orthe G30 MINI diesel tel W18, 4. HT12 Greon) #12 must rot be mitod wth the coolant or the G30 MINI disso uel 6 '5. 630 Pink) nust be used ony forthe MINI dasel fuel W16. G30 must not be ile nthe other coolant ctcults or mixed wth the other cootants.Eee Damage tothe engine. The use ofan incorrect coolant may lead to corrosion o gelling inthe angi “+ Use only approved coolants forthe spectc venice. "+ Filthe vehi only wth the coolant wth whch & was delivered ox works. "+ Noconlycompattle coolants. The colour does not alow any assessment abou the compat of coolants |p Sebctontte cone conta ny meant par J + Seloct a suitable adapter (¥) rom the set of special tools 0404 417 (17 0100 Tyee Engine earn 46/048 58 Adaptor) fom 170 100, + The uid tank ofthe vacuum filer doviee must be Sled wih 1 Ilo 2Imore than the spectod eapacty of coolant forthe vanile. Capacity of low-temperature coolant crcult G20 '488200 1184882001 (Low-temperature coolant 421 ‘reut) Expendable materials: Techneally sutable attreeze and consion nhibtor + Connect the sslactod adapter (Y) tothe coolant exeansion tank + Connect vacuum far dovie to connection (x) ofthe adapter. + Chockthatshutot vats and (8) of he vacuum fle doves (1) ae closed. + Connect andock conn sion (X) 0 the coolant expansion tank. + Connect Ventur nozzle (1) othe vacuum lr devies (2). es (00/5 the connection on the oolant expansion tank [7 Satta ca) * Connect compressed ak(1)Test vacuum + Open shut-of valve (8). ‘he venturinozzle produces & fow nose. + Open shutot vate (A) unt th + Close shutot valve (A) again >The ling nose (1) has now’ uel fing hose (1 is ul Wehout bubbles, sanded, ‘+ Chock he coolenthoses for porosity and renew porous coolant hoses as roquted. SSE ‘The coolantnoses contract dueng vacuum buld-p, + AAtora vacuum of 07 to 0.95 barhas been created in tho coolant crcl (duration approx. 2 mi), shulthe shut vate (8) “+ Check wrethar the snuto valves (A) and (8) ae closed. + Disconnect the Vartur nozzle (1) heck +The vacuumin the olan ckcut must be maintained fo at last 0 seconds Result > Vacuum sop. ropa iad stat tho ting procedure trom th begining.+ The vacuum nthe coolant ckcut must be mantaned for al least 30 seconds Test vacuum Result > Vacuum remains constant Measure + Continue wth fling, + Koop shut valve (8) closed during the fig procoss. + To the cooling system, open the shutot valve (A) tothe fis tank ofthe vacuum fer device + Stop the fling procedure when the noecle in the prossure massurng device ison O bao longer drops, ltnecessay, reduce remaining vacuum. In order do so, open shutof valve (8) ‘+ Remove the vacuum fer device wih the adapter tom the bu-temperaute coolant expansion tank o ‘Adust the coolant even the temperature coolant expansion tank (1) upto the lower edge of the coolant ier neck (2) othe lelemperature coolant expansion tank). ‘ato fling the cooling system wth the vacuum fir dove, also run the cootng systom bleedng routine, — max oan MAIN WORK. 2 Bleeding the low-temperature cooling system oa Leong filo coolant! Do not reuse used coolant, |Wihon replacing and omoving components which aly onthe corrosion protection efoct ofthe coolants essential to change the coolant. ‘The cooing aystem must therefore be emptied and reflod. Inthe case of ether removal workinvaWing the draining of pat quantities of coolant, the coolant vel must be topped up with new coolant.Fang without ne vacuum fer dove (natoing ca ing) snot permite | Non-comlance wrest in cangerafcomporent damage andor engre damage. 1 Fang speceaton absolutly must bo achoredo “The operation ofthe vohicl is not permitted unless the fling procedure has been completed. Otherwise, funciona mations (degradation) andlor overheating may occu. ‘Ableecng procedure required aera parthas been exchanged nthe cooling system andr ate reling the coolng system. Scan Before staring tha automatic cooling system beading routine, make sure that allcoolant circuits ae filed. tne cooling systam bleeding roulina is started while one ofthe coolant ercul is ply, there sa isk of damage othe elctfe coolant pump when running i ry “Make sure that terminal 15 isnot disconnected fo the bleeding procedure. Switch on lbw-boam heasighs and hazard wari lights. tho bbwrboamhoadignts and nazaré watning Ils ave rot swchod an, tho gniton terminal 15) wll such of automatealy ator conan por of lime and nterup the Bleeding procedure, cay ‘The iving experience swteh must net be seo the EGO PRO swich positon, [Adust the coolant levelinthe temperature coolant expansion tank 1) upto lower edge (2) ot the coolant ier neck of bwtemperature coolant expansion tank (1) ‘+ Close the sealing cap onthe coolant expansion tank o the temperature coolant crcl. ‘+ Ensure thatthe bonnets pen + Connect baller charger. “+ Switch onthe ignition and eneure that & remains ewitched on (fo example, activate the bw-beam headight ara the nazaré waning Its atthe same te), + lithe lowbeam headight and he hazare warning Ight are not switched on the igntion (terminal 15) wilswich of autematcaly ater some time and interupts the bleeding procedure ‘+ Ensue thatthe Driving Experience Contos notin the “ECO-PRO” swich postion. ‘+ Adjust the heating to maximum temperature and adjust the blower fo the lowest stage. + Hold the accelerator pedal down othe lit postion for atleast 108 and do not press on the brake pedal + Do net stat ongine The cooling system bleeding ovtne wllstar. ‘The electric coolant pump inthe lowtemperatue coolant ctcut is activated for 11 minutes according tw acooling system bleeding routine The cooling systambleeding routine ends ater *1 minutes. The electri coolant pump is no longer activated. ‘+ Note the display inthoinstumont cluster (KOMB), the sonvize turetionisintorupted, the costing system bleeding routine mustbe repeated ‘+ Alow he coolant temperature to cooldown to <50%C. Loosen sealing cap (1POSTPROCESSES ‘Aner the cooling system bleeding routine, the cooing systems topped up above the maximum mak. ‘Overtng the cooling systom serves to balance the remaining abn the cooing system, ‘The normal iling bvsl othe coolants reached whip cving ‘+ Adjust the ting Wvelincootant expansion ank 2) ofthe bwetemperature coolant cuit 100 md above the maximum mark (1) + Close seating cap (1). '3~ Checking low-temperature cooling system for watertightness a Hot surfaces. Risk of burning! + Perio a work only on components that have cooled down. x cam» c Bull up excose prossure and wa fr approximately 2 minutes Opening pressure of sealing cap /test pressure of high-temperature coolant elcut cooling systom Pressure rllet valve opens when the pressure min. 14 bar ‘exceeds the ambient pressure Electr changeover valve must open at latest max. 0,1 bar ‘shan the pra pressure “Test prossure fr cooling system (gauge 1 sbar prossuro)ie described tat taps ot completed sucess repels sop wc, Ol relace Se tag esp ehrtibe unesethsnicomectopenog ase When rgat igh arti ergarture, te Seg ma cave te pose rata vae wernt Corer nesarisaseene eetwerichcaseuescsan te cert cancers ctnateratte sat cobunentne naive: wee tc Deve eaha eltan nto wares ceclone er bene evar he sara apie delecive or nat Escaping coolant vapours when the vehite is at stan ing cap. This may cause an peomect may cause the pressure rele valve to ing pressure ng aaa err (470 100 + Bull up the prossuro wih special tools 0494 418/17 0101) and 0.4419 (170102, tomthe set ot special tools 0488 217 370100), ‘+ Observe onthe prossure measuring dovio when tho opering prssur has boon reached. Opening pressure of sealing cap /test pressure of high-temperature coolant circu cooling system (1) on speciatoo!0 425 889 (17 0118) tom the set of specialtook Pressure rliot valve opens when the pressure min. 14bar sexcoeds the ambient pressure, Electric changeover valve must open at latest max. bar ‘whan the prossure is lower than the arent pressure. “Tost prossure for cooling system (gauge 18bar pressure) + Close seaing cap). Information Overview of Special Tools 0.496.417 (170100) Testor ssc se 130.494.418 (170101) Pump common ere radator cap. Inctudes nthe tool or work Storage ection Invited Feplacod by In connection wth shNumber 01 0702 884) Consisting of Pos BMW Order number Replcod by 5 098-420(170 105) 10 0494427 (170911) 10494418 (170101), 2 0498.410(170 102) 30498 420(170 108) 4 0.496.421 (170 108) 8 0.498 495 (170 106) 7 0498-424(170 107) 8 0498-425 (170 108) @ 0.498.426 (170 109) 11 0404 428 (170112) 12 049482 (170119) 13. 0494649170114) 140496 880 (170118) Common Usage Includes inthe toolorwork 0.498.417 Storage bation Roplacod by Inconnecton wth shNumbor For checking engine cooing systom on watorighinoss. For chocking Designation ‘Adapter For radiator cap (sawtooth thread) ‘Adapter Forraditor cap RSI, REO adapter replaced 17 0082. Pump Hose {hase with quekolease couning) ‘Adapter Forradator cap (normal thread) ‘Adapter Forraditorcap(normaltivead) ‘Adaptor Forradator cap (sawtooth thread) ‘Adapter Forradiator cap R50 /W10 ‘Adapter Forradatorcap RSO/W10 ‘Adapter Forradiator connection RSM, FASONT7 adapter comesponds 13 170081 case ‘Adapter For radiator cap Model soios:E0, E61, £68, B54 Slo 1 0802 (688) ‘Adaptor Forradatorcap Model series: E50, E61, E63, E68 Sno. 1 08 03 (968) ‘Adaptor For radiator cap Model sorios: N12, Nia Irconnection wth wanesp 30404 419 (170102) Hose Geno ttn 8 nace (hose wth quserlease cvahg) hsesintetolorvane 0484417 ‘Storage bcaion Raplaced oy Incomectan th sisunber 0.484 426 (170108) Adaptor Common eetinsip 8 For radiator connection REST, RSOWI7 adaptor commosponds to 17 ost Included inthe toolorwork 0 404.417 Usege Storage leeation Foplacod by In connection wth shNumber 0.485 89 (170115) Adaptor Common weetneee 8 Usage Forvaditor cap Model sofas: N12, N14 Inchudesinthe toolorwork 0404 417 Storage ection Foplacod by In connection wth shNumber 0128008321) Overview Technical Data pening prossure of sealing cap /tost pressure of hightomperature coolant cicult cooling systom veetioie 8 Pressure rll valve opens when the pressure exceeds the amblent, rin Aber pressure, Elect changeover valve must open at latest when the pressures max 0,1 bar lower han he ambient pressure ‘Test pressure for cooing system (gauge pressure) 1sbar Capacity of low-temperature coolant eircult G20 teccnap 1 (8488200 1184882001 (Low-temperature coolant cre) 421 Expendable materials: Technically sutabe aitieeze and cortosion torLinks, Repair instructions 17°00. Notes for working on cootng system Operating materials Mah group 17 Used instep 1 Usedinstep 11700 009. Check the cooling system for watertightness with the special tool 41 Check the high-temperature cooling system for watertightiness an Hot surfaces. Risk of burning! + Perform all work only on components that have cooled down. + Loosen seating cap (1). Pressure rll valve opens when the pressure min. 14 bar ‘exceeds the amblent pressure, Ect changeover valvo must opon at flost max. bar ‘shor the prossureis lower than the arbisnt, prossur. “Test pressure fr cooling system (gauge spar pressure) ‘TECHNICAL INFORMATION Ifthe described test step isnot completed successfully: repeattest stop twice. Only replace the soaing cap after tree lasts with an Incorect oping pressure, \Whan civng at high ambiont temperatures, the dasign may cause th pressure rola valve in the sealing ea o oper slighty and ao escape Logethor wth dissolved coolant. Ths coolant Vapour condenses an the surace ofthe coolant expansion tank ang loaves aces of coolant lahen the verte has coobd down, These traces of cant do not heate whether the sealng ‘apie dotecive or nat Escaping coolant vapours whon the vehi isa standstill may cause the prossur rele valve to Sickie tho seating cap. Tis may cause an ncoroct pening prossure. Ing cap (1) on special tool0 498 643 (17 0114 tom the go of specaltook ‘Baik up the posure wth special took 0.404 418/17 0101) ana 0.494 410 (170 1021 tom the eat of special tool 0494 417 170 100) ‘+ Observe onthe prossure measuring device when the opering pressure has boon reached. Opening prossurs of saling cap /tost pressure of high-temperature coolant circult cooling systom Pressure relief valve opens when the pressure min. 14 bar ‘exceeds the ambiontprossure. Electr changeover vale must open at latest max.0,1 bar ‘shor the proseure ls ower than the arbent pressure. “Tost pressure for cooling system (gauge 15bar pressure)+ Close seatng cap (1). Close the sealing cap (1) unttne arrows are us 2 Checking low-temperature cooling system for watertightness Hot surfaces. Risk of burning! + Pertmallwork only on componeris that have cooled down. Bulb up excess prossure and was for approximately 2 minutes Opening pressure of sealing cap /test pressure of high-temperature coolant circuit cooling system Pressure rll valve opens when the pressure rin. 14 bar ‘exceeds the amblant pressure. eat cri changeover vaa must open at ost max 01 bar GEE) > 1.8b0r “Test pressure for cooling system (gauge pressure)Information Overview of Special Tools 0.494.418 (170101) Pump 0.494.419 (170102) Hose Ifthe doscrbed test stop isnot completed successfully: repeat test stop twice. Only replace the sealing cap after three tests with an incorect opening pressure. \When ctvng at high ambiont temperatures the dosign may cause th pressure rola val in te sealing capo open slightly and aio escape together wih dissolved coclant. Ths coolant ‘Vapour condenses an the sutace ofthe coolant expansion tank ang loaves races of coolant ‘hen the vehicle has coobd down. These traces of coolant do not late whothor the sealng ape delecive or na Escaping coolant vapours when the vehite sat stan ing cap. This may cause an neomect may cause the pressure rele valve to ing pressure (1) on speciato!0 425 889 (17 0116) tom the set of specialtook pee 171370 100, + Bulls up ne pressure wi special tools 0404 4161700 101) and 9.426419 (17 0102) Homthe set ot spect tool 0.208.417 (17 0 100) ‘+ Observe onthe prossure measuring dovio when tho opering prssur has boon reached. pening pressure of sealing cap /test pressure of high-temperature coolant circu cooling system Prassurerllot valve opens when the prossure min. 14bar sexcoeds the ambient pressure, Elect changeover vale must open at latest max. 1 bar ‘whan the prossure is lower than the arent pressure. ‘Tost prossure fo cooling system (gauge 15bar pressure) + Close seaing cap). Common ssc snp 12 Usage Inchudea nthe toolorwork 0.494.417 Storage ection Replaced by In connection wth ShNumber Common ssc sp 12 Usage (hose wth quekroloaso couping) Inctudea inthe toolorwark 0.498.417 Storage ection Foplacod by In connection wth shNumber0-496 642(17 0113) Adaptor 0.496.417 (170100) Testor ‘Pes BMV Order number Common ee) Usage. Forvadiator cap Model sores’ E60, E61, E69, E64 SIno.1 0803 (288) Included inthe toolorwork 0.498.417 Storage loeation Replaced by In connection wth siNumber Common Usecinsep 12 For checking engine cooing sy radar cap. — ym on wateighness. For checking Inctded inthe tool or work Storage beation Replaced by In connection wth siNumber Ihave! 010702684) Consisting of ‘Replaced by Designation Tn Connection wth ‘Adapter For radiator cap (sawtooth threaa) ‘Adapter For adator cap RSQN11, AEOW17 adapter replaced 17 0052 5 0.498.422(170 105) 10 aaaeaz7 (7011) + 0494419 (170101), Pump Hose 2 949s 41917 0 102) (hase wth quekrolease couping) BN cacucuaoied Fortatrcap (roma rea 4 o4nesa 170100) Fortra (oma wea) eases 17 ofc Forradatrcap (smoothness) 7 essaaaecs7o%07 Ferrarini ‘Adapter eae) Foradtorcap 5010 ‘Adapter Forradator connection RSQ, [RSOIWI7 adapter comesponds to rroost 8 0498-426 (170 100) 11 0498-408 (170 112) case ‘Adaptor For adatorcap Mode series: E80, E61, E63, E64 Sino. 1 08 08 (988) 12 a4osst2 (170113) ‘Adapter 13. 0494649 (170114) For adator cap Model soos: £50, E61, E69, 2o4 Sino. 108 09 (288) ‘Adapter 14 0496 889 170115), For adator cap Model series: N12, nia0 494 643 (170114) Adaptor Geom tte nace Fora eap Model auras E50 Ei, BS, E54 Sn. 1 080 (08) Ihsesin te tolorvane 0484417 storage bcaion Raplaced oy Incomectan th stsunber 0.494 426 (170108) Adaptor commen ess anp 2 For radiator connection REST, RSQWI7 adaptor commosponds to 17 ost Inchudedinthe tool orwork 0494-417 Storage eeation Feplacod by In connection wth Usage stNumber 0 495 889 (17 0115) Adaptor commen sctinssp 2 Usage Forradiator cap Model sorias: N12, N14 Inchudes inthe toolorwark 0494-417 ‘Storage bation Foplacod by In connection wth shNumber 025008321) Overview Technical Data pening pressure of sealing cap /tost pressure of hightemperature coolant circult cooling system Usecinne 12 Prossureralit valve opens when the prossure excoods the ambient rin 1Abar pressure, Elect changeover valve must open t latest when the pressure is max 0,1 ber loworthan he ambient pressure ‘Test pressure foreoolng eystem (gauge pressure) 1 sbar1700 008 Draining and topping up coolant for high-temperature circuit PRELIMINARY WORK 1—Removing the acoustic cover | UY 8 ee Hot surfaces. Risk of burning! + Perform all work only on components that have cooled down. Pees Damage to the acoustic cover. Jerky movements during disassembly and excessive application of force during installation may result in breakage of the acoustic cover. “+ Disassemble ormount the acoustic cover caretuly. 1 Disassemble or mount snap-lock coupings ofthe ballpvots one alter the other. Disassemble of mount acoustic over only a temperatures >20 °C. Use only distiled water as an auxiliary material during instalation, no ubricants + Unclip the acoustic cover (1) trom the holders in the marked areas towards the top, 2.— Removing the clean air pipe with the resonator eee Hot surfaces. Risk of burning! + Perform all work only on components that have cooled down,‘Unlock the locks (1) ‘+ Feed the engine ventilation line (2) out and set it aside. ‘+ Unlock plug connection (1) and disconnect + Loosen clamp (2). + Unfasten clamp (3). ‘+ Separate the clean air pipe with resonator from the intake fiter housing. ‘+ Press and hold clean air pipe with resonator (1) inthe direction of the arrow, + Unlock and disconnect the tank ventilation line (1). + Loosen the clamp (arrow). ‘+ Unlock plug connection (1) and disconnect ‘+ Unlock the clamp (2) ‘+ Feed out clean ar pipe with resonator (3) and remove. 3 Removing the acoustic cover for the engine at the front‘+ Unlock plug connection (1) and disconnect. + Loosen clamps (2). ‘+ Remove the wiring harness section (3) and put to one side. + Loosen clamp (1). + Detach all expanding rivets (1) + Guide the acoustic cover (2) out and remove, + Version 1: Remove screws (arows). Feed front underbody protection (1) backwards out of the bumper panel. 05106222 ‘| Gyn vein? L SS eee Remove screws (arrows). v 4 WEQY, Cuide out ont underbody protection (1) and remove i. ie .+ Version 3: Romove screws (arows). Guide out front underbody protection (1) and remove it. + Version 1: Unscrew the screws (arrows) of the wheel arch cover on wheel arch cover. Fold the bottom whe: Loosen screws (1) Remove underbody protection of the steering gear (2). arch coverto the side. + Version 2: Loosen screws (1) Remove the holder of the underride protection (2) Loosen screws (3) Slide the steering gear underbody protection (4) out and remove. 6 - If installed: Removing the steering start protection Prerequisite ‘The front underbody protection is removed, + Loosen screws (2). + Remove guard (1). MAIN WORK 7 — Draining the coolant from the high-temperature cooling systemHot surfaces. Risk of burning! ‘+ Porform all work only on components that have cooled down. Lc Life-iong fill of coolant Do not reuse used coolant. ‘When replacing and removing components which rely on the corrosion protection effect of the coolant, itis essential to change the coolant. The cooling system must therefore be emptied and refilled. Inthe case of other removal work involving the draining of part quantities of coolant, the coolant level must be topped up with new coolant, ec ane Collect and cispose of emerging fuids. Observe country-specific waste disposal regulations. + Loosen sealing cap (1). ‘+ Unlock and loosen coolant line (1). + Catch and dispose of escaping coolant. + Unlock and loosen coolant line (1), ‘+ Catch and dispose of escaping coolant.‘8 — Connecting the coolant lines for the high-temperature coolant circuit 1cks must engage audibly. ‘+ Check the sealing rings (1) of the coolant lines (2) for damage and renew if necessary. + Connect and lock coolant ine (1). Coolant line (1) must audibly engage. POSTPROCESSES 9 Install the acoustic cover for the engine at the front + Che ck it acoustic cover (2) in marked area (1) is damaged and replace acoustic cover (2) iinecessary. Parts: Acoustic cover‘+ Thread in and position the acoustic cover (2). ‘+ Mount allexpanding rivets (1). ‘+ Feed in and position wiring harness section (3). + Secure clamps (2). + Connect connectors (1) and lock, ‘The connector (1) must engage auciby. + Secure clamps (1). 10 ~ Installing the clean air pipe with resonator ‘+ Check the seal(1) for damages, replace if necessary. » Replace damaged gasket TECHNICAL INFORMATION Do not use pointed or sharp-edged tools for the installation andior removal.+ Remove damaged so: ‘+ Clean gasket groove (1) with a dry towel The gasket groove (1) must be clean. + Renew gasket. Parts: Gasket ‘+ Install seal dry without lubricant or mounting agent. Msc ad Incorrect assembly is possible. Ensure correct installation position. + Feedin and install the seal ‘+ Make sure the seal is correctly installed in the gasket groove (1). ‘+ Make sure that the sealing ip (2) is pointing downwards (see figure). ‘+ Guide in and installthe clean ai pipe with resonator (3). + Lock clamp (2) ‘The clamp (2) must engage aulbly. + Connect connectors (1) and lock. ‘The connector (1) must engage audibly. + Secure clamp (arrow). ‘+ Press and hold clean air pipe with resonator (1) inthe direction of the ‘+ Connect and lock the tank ventilation tne (1)‘+ Connect the clean afr pipe with resonator to the intake fiter housing. + Tighten clamp (3). Clean air pipe to upper section of intake filter housing ‘clamp Tightening 3Nm torque ‘Secure the clamp (2). ‘+ Connect connectors (1) and lock. ‘The connector (1) must engage aucibly. Insert and installthe engine ventilation line (2). Ensure that the locks (1) engage aucibly. 11 — Install acoustic cover Pees Damage to the acoustic cover. Jerky movements during disassembly and excessive application of force during installation may result in breakage of the acoustic cover. Disassemble or mount the acoustic cover care‘ully. Disassemble or mount snap-lock couplings of the ball pivots one after the other. Disassemble or mount acoustic cover only at temperatures >20 °C. Use only distiled water as an auxilary material during installation, no lubricants. ‘+ Check allrubber mounts (1) of acoustic cover (2) for correct seating, ‘+ Clipin the acoustic cover (1) into the holders in the marked areas. Tho acoustic cover (1) must audibly engage into place. i.12~Fill the high-temperature cooling system with the vacuum filer device Vacuum filer device ‘Vacuum ler device - connected to the coolant expansion tank 1 Vacuum filler device with pressure gauge and shutoff valves, 2 Filling hose 3 Fluid tank with coolant 4 Venturi nozzle 5 Compressed air connection (maximum of 6 bar) 6 Outgoing hose (lead out-going hose into a collecting vessel) Prerequisite The coolant expansion tank for the cooling system must be empty. The fluid tank of the vacuum filler device must have a sufficient quantity of premixed coolant, 1| to 21 more than the specified capacity for the vehicle. The fuid tank of the vacuum filler device must be positioned at the same height as the coolant expansion tank. The ‘compressed air connection must have a pressure of 6 bar. Ignition is switched off Ecce Scand Follow notes for repair work on the cooling system. For additional information see: Main group 17 1700 .. Notes for working on the cooling system Rice ncaa Life-iong fill of coolant! Do not reuse used coolant ‘When replacing and removing components which rely on the corrosion protection effect of the coolant, itis essential to change the coolant. The cooling system must therefore be emptied and refiled. Inthe case of other removal work involving the dtaining of part quantities of coolant, the coolant level must be topped up with new coolant.Mice Somoneud Filing without tne vacuum filer device (watering can filing) is not permitted. Non-compliance will result in danger of component damage andior engine damage. Fillng specification absolutely must be adhered to. ‘The operation of the vehicle is not permitted unless the filing procedure has been completed. Otherwise, functional limitations (degradation) and/or overneating may occur. bleeding procedure is required after a part has been exchanged in the cooling system andior ater refillng the ‘cooling system. Lice mca Make sure that the ignition (terminal 15) is switched off prior to creating the vacuum with the vacuum filer device, > Observe the coolant typeCoolant in the vacuum filer device container cas. 3 : | 20 ura MINI Diesel 16 3) 17 195 ‘Choose the correct coolant for Ring Avvehicle must be filed wth the coolant with which itis delivered ex works 41. G48 (Blue) G48 must not be mixed with the iSCoolant or the G30 MINI diasel fuelW16. 2. 13 coolant (blue) is used only for the 13 heater circu. 13 coolant must not be filed in the other coolant cicuits or mixed with the other coolants. ‘3. HT12 (Pink) HT12 must not be mixed with the i3 coolant or the G80 MINI diesel fuel W16. 4, HT12 (Groen) HT12 must not be mixed with the i3 coolant or the G30 MINI diese! fuel W16, 5. G30 (Pink) must be used only for the MINI diesel fuel W16, G30 must not be filed in the other coolant circuits or mixed with the other coolants. Pees Damage to the engine. ‘The use of an incorrect coolant may lead to corrosion or gelling in the engine, | + Use only approved coolants for the specifc vehicle. | + Filthe vehicle only with the coolant with which it was delivered ex works. Mix only compatible coolants. The colourdoes not allow any assessment about the compatibility of coolants. Selection of the correct coolant only by means of the part number.‘+ Selecta suitable adapter (Y) from the set of special tools 0.494 447 (17 0 100) Type Engine ‘Adapter (Y) ftom 170100 Gzoices [846/848 B58 170118 + The fuid tank of the vacuum filer device must be filed with 1 Ito 2 Imore than the specified capacty of coolant for the vehicle. Capacity of high-temperature coolant circuit G20 8488200 1/84882001 98! Expendable materials: Technicaly suitable antieeze and corrosion inhibitor + Connect the selected adapter (Y} to the coolant expansion tank, rx + Connect vacuum filer device to connection (X) of the adapter. + Check whether shut-off valves (A) and (B) of the vacuum filer device (1) ‘+ Connect Venturi nozzle (1) to the vacuum filer device (2). (iis the connection on the coolant expansion tank. 7.448 pi + Connect compressed air (1). ere (Xs the connection on the coolant expansion tank. Se F BYTEST VACUUM ‘+ Open shut-off valve (8), The venturinozzle produces a flow noise. ‘+ Open shutoff valve (A) until the fuel fing hose (1) is full without bubbles, ‘+ Close shutoff valve (A) again. > The filing hose (1) has now been bled ‘+ Check the coolant hoses for porosity and renew porous coolant hoses as required, Rc en ‘The coolant hoses contract during vacuum build-up, ‘+ After having established a vacuum in the coolant circuit of between -0:7 to -0.95 bar (duration approximately 2 min), close the shut-off valve (B). ‘+ Check whether the shutoff valves (A) and (B) are closed, + Disconnect the Venturi nozzle (1). Check ‘+ Make sure the vacuum in the coolant crcutt is maintained for at least 30 seconds, Result > Vacuum drops.Measure + Look forthe leak, repair it and start the fling procedure from the beginning Check ‘+ Make sure the vacuum in the coolant ctcult is maintained for at least 30 seconds. TEST VACUUM Result > Vacuum remains constant, Measure + Continue with fling, + Keep shutoff valve (B) closed during the filing process. + To filthe cooling system, open the shutoff valve (A) to the fuid tank of the vacuum filer device + ‘Stop the fling procedure when the needle inthe pressure measuring device is on 0 bar or itn longer drops. + Hfnecessary, reduce remaining vacuum n order to do so, open shutoff valve (8). Remove the vacuum filer device with the adapter from the high temperature coolant expansion tank (1) ‘Top up the coolant levelin the high temperature coolant expansion tank (1) to the lower edge of the coolant filer neck (2) in the high temperature coolant expansion tank (1). Ater fling the cooling system with the vacuum filer device, also run the cooling system bleeding routine, 13 — Bleed the high-temperature coolant circuit‘TECHNICAL INFORMATION Life-long fill of coolant! Do not reuse used coolant ‘When replacing and removing components which rely on the corrosion protection effect ofthe coolant, itis essential to change the coolant. The cooling system must therefore be emptied and refiled. Inthe case of other removal work involving the draining of part quantities of coolant, the coolant level must be topped up with new coolant. Mice oman Filing without the vacuum filer device (watering can filing) is not permitted. Non-compliance will result in danger of component damage andlor engine damage. Filing specification absolutely must be adhered to ‘The operation of the vehicle is not permitted unless the filing procedure has been completed. Otherwise, functional limitations (degradation) and/or overneating may occur. Ableeding procedure is required after a part has been exchanged in the cooling system andior ater refiling the ‘cooling system. ‘TECHNICAL INFORMATION Betore stating the automatic cootng system bleeding routine, make sure that all coolant circuits ae filed. the ‘cooling system bleecing routine is started while one ofthe coolant circuits is empty, there is arisk of damage to the ‘electric coolant pump when running it ry Make sure that terminal 15 is not disconnected forthe bleeding procedure. Switch on low-beam headlights and hazard warning light. the low-beam headlights and hazard waning lights are not switched on, the ignon (terminal 18) wil switch off automaticaly after a certain period of time and interrupt the bleeding procedure. Mien Soca aud ‘The driving experience switch must not be set to the ECO PRO switch position,pen the bleeder screw on the coolant expansion tank for the high+ temperature coolant circuit and close it again after approx, 10's, You can close the bleeder screw por to expiry of the 10 s once coolant escapes. Adjust the coolant level inthe high temperature coolant expansion tank (1) ‘to the lower edge (2) of the coolant filer neck of the the high temperature coolant expansion tank (1) Close the sealing cap on the coolant expansion tank of the high~ temperature cooling circu. ‘+ Make sure the bonnet is closed, Make sure that the wheels touch the ground. Engage the parking brake. Do not engage any gear in manual-shit gearbox, and engage the gear to "Por N’ automatic transmission. Connect battery charger, ‘Switch on the ignition and make sure that it remains switched on (for ‘example, activate the low-beam headlight and the hazard warning light at the same time). IMthe fow-beam headlight and the hazard waming ight are not switched on, the ignition (terminal 15) willswitch off automatically after some time and interrupts the bleeding procedure. Check that the driving experience control is notin the "ECO-PRO" switch posttion. ‘Adjust the heating to maximum temperature and adjust the blower to the lowest stage. Hold the accelerator pedal down to the limit position for at least 10's and do no kick the brake pedal. Start engine. Start the cooling system bleeding routine, pay attention to the display on the instrument cluster (KOMBI). ("Service function started’ ‘The engine speed (up to 3500 rpm) and the actuators in the cooling system are activated automatically for 11 minutes according to a cooling system bleading routine, ‘The cooling system bleeding routine ends approx. 11 min after the engine starts. Tho engine speed drops to the idle speed. (Observe the display in the instrument cluster (KOMB).. Itthe service function s interrupted, the cooing system bleeding routine mustbe repeated, Switch off engine, ‘Allow the coolant temperature to cool down to < 50°C. Loosen sealing cap (1).Ecc iene ‘Atter the cooling system bleeding routine, the cooling system is topped up above the maximum mark. Overfiling the cooling system serves to balance the remaining arin the cooling system, ‘The normal fling level of the coolant is reached while driving, ‘+ Adjust the filing levelin the coolant expansion tank (2) of the high- temperature coolant cicult to 200 mi over the maximum mark(1) . + Close sealing cap (1). ‘+ Olose the sealing cap (1) untithe arrows are flush. 14 If installed: Installing the steering guard Prerequisite ‘The front underbody protection is removed, + Remove guard (1) + Tighten the screws (2) Bumper buffor device staoring on front axle support Mio Tightening 56Nm torque ring gear 15 — Install the underbody protection of the st+ Version 4: ‘+ Position the underbady protection of the steering gear (2). Hexagon Tightening 3Nm screw for torque thermoplastic Hexagon Tightening 8Nm ‘screw M6x20 torque ‘+ Position the bottom wheel arch cover. + Tighten the screws (arrows) of the bottom wheel arch cover on the wheel arch cover. Wheelarch cover (screws) ‘Thermoplastic Tightening 3Nm hexagon torque ‘screw + Version 2: ‘+ Guide in the steering gear underbody protection (4) and instal, + Tighten the screws (3) Underbody protection of the steering gear Hexagon Tightening 3Nm ‘screw for torque thermoplastic Hexagon Tightening 8Nm ‘screw MBx20 torque + Position holder of underride protection (2) + Tighten the screws (1). Holder underride guard to front axle suppor Mio Tightening 56Nm torque 16 — Installing the front underbody protection 85106222 + Version 1: Feedin the front underbody protection (1) towards the front under the bumper panel and position. Tighten screws (arrows). Underbody protection front Hexagon Tightening 26Nm ‘screw for torque thermoplastic, Hexagon Tightening 8Nm screw M6x20 torque+ Version 2: Feed in and position the tront underbody protection (1). Tighten screws (arrows). Underbody protection front Hexagon Tightening screw for torque thermoplastic, Hexagon Tightening ‘screw M6x20 torque + Version 3: Feed in and instal front underbody protection (1). Tighten screws (arrows). Underbody protection front Hexagon Tightening screw for torque thermoplastic Hexagon Tightening screw M6x20 torque Additional Information Overview of Tightening Torques Clean air pipe to upper section of intake fiter housing Clamp Tightening torque Bumper buffer device steering on front axle support M10 Tightening torque Underbody protection of the steering gear Hexagon screw for Tightening torque thermoplastic Hexagon screw M6x20 Tightening torque Wheel arch cover (screws) ‘Thermoplastic hexagon, Tightening torque screw Holder underride guard to front axle support 2.6Nm 8Nm 26Nm 8Nm Used stop 10 3Nm Used n stop 14 86Nm Used a stop 15 3Nm 8Nm Used n stop 15 3Nm Used stop 15 mo Tightening torque 56Nm Underbody protection front sadn sop 16 Hexagon screw for Tightening torque 2,6 Nm thermoplastic Hexagon screw M6x20 Tightening torque 8Nm Overview of Special Tools 0.494 417 (17 0 100) Tester Common Used a sep 12Usage Included inthe toot orwork Storage cation Replaced by In connection with StNumber Consisting of Pes tmbor 5 0494422 (170 4105) 0.494427 (170 10 an 1 0404418 (170 101) 2 0494419 (170 102) 3 0494420 (170 +103) 4 0494421 (170 108) 5 0494425(170 4106) 7 0494426 (170 4107) 3 0494425 (170 108) 9 0494426 (170 +109) 1 0494 428 (170 112) 0.494.642 (170 12 413) For checking engine cooling system on watertightness. For checking radiator cap. Individual 0107 02 (884) Replaced o Designation Connection by wth ‘Adapter Fortadiator cap {sawtooth thread) ‘Adapter Forradiator cap REGIW11, REOW 17 adapter replaced 170 052. Pump: Hose (hose with quick-release coupling} ‘Adapter For radiator cap (normal thread) Adapter For radiator cap (normal thread) Adapter For radiator cap {sawtooth thread) ‘Adapter For radiator cap R50/ wio ‘Adapter For radiator cap R50/ wio Adapter For radiator connection RSGIW11, REOW 17, ‘adapter corresponds to 170051 Case ‘Adapter For radiator cap Mode! series: £60, E61, E63, 64 SI no.: 1 08 03 (988)Adapter po 0894649 (170 Portada cap Mode ‘8 Sor: £50, Eb, 20. ee Sino 1086 (68) Aaaptr v4 9/95 4800170 Porradaor cap Mode series: N12, N14 Overview Technical Data Capacity of high-temperature coolant circuit G20 1B48B2001/84682001 Used stop 12 eal Expendable materials: Technically suitable antiteeze and corosion inhibitor Links Repair instructions Used in step 1700 ... Notes for working on cooling system. 12 Operating materials Used in step Main group 17 121700011 Draining and topping up the coolant for the low-temperature circu Prerequisite + Switch off ignition. PRELIMINARY WORK 1—Removing the front underbody protection + Version 1: Remove screws (arrows). Feed front underbody protection (1) backwards out of the bumper panel. + Version 2: Remove screws (arows). Guide out front underbody protection (1) and remove it. + Version 3: Remove screws (arrows). Guide out front underbody protection (1) and remove it. + Version 1: Unscrew the screws (arrows) of the wheel arch cover on wheel arch cover, Fold the bottom wheel arch cover to the side. Loosen scrows (1) Remove underbody protection of he st ring gear (2).+ Version 2: Loosen scrows (1) Remove the holder of the underride protection (2). Loosen screws (3) Slide the steering gear underbody protection (4) out and remove. 3-If installed: Removing the steering start protection Prerequisite ‘The front underbody protection is removed. + Loosen screws (2). + Remove guard (1). MAIN WORK ‘4~Draining the coolant from the low-temperature cooling system Hot surfaces. Risk of burning! + Perform all work only on components that have cooled down, ‘TECHNICAL INFORMATION Life-iong fill of coolant! Do not reuse used coolant ‘When replacing and removing components which rely on the corrosion protection effect of the coolant, tis essential to change the coolant. The cooling system must therefore be emptied and refiled. Inthe case of other removal work involving the draining of part quantities of coolant, the coolant level must be topped up with new coolant. Msc aman Collect and dispose of emerging fuids. Observe country-specific waste disposal regulations.+ Loosen sealing cap (1) + Loosen screws (1). ‘+ Guide out and remove bottom left cover (2) to the front. + Unlock and disconnect the coolant line (1) ‘+ Catch and dispose of escaping coolant. POSTPROCESSES 5—Connecting the coolant lines for the low-t smperature coolant circuit Lec ee Make sure that the connections are locked correctly. The locks must engage aucibl ‘+ Check the sealing rings (1) of the coolant tines (2) for damage and renew if necessary.‘+ Connect and lock the coolant line (1) + Tighten the screws (1). Cover, front bottom on side Hexagon ‘screw for thermoplastic 6 Filling the low-temperature cooling system with the vacuum filler device Vacuum filer device ‘Vacuumfiler device - connected to the coolant expansion Tank =— 1 Vacuum filler device with pressure gauge and shutoff valves 2 Filling hose 3 Fluid tank with cootant 4 Venturi nozzie 5 Compressed air connection (maximum of 6 bar) 6 Out-going hose (lead out-going hose into a collecting vessel) Prerequisite The coolant ine (1) must audibly engage, + Feed in and install cover (2) at the bottom front lft. Tightening 3Nm torque‘The coolant expansion tank for the cooling system must be empty. The fluid tank of the vacuum filler device must have a sufficient quantity of premixed coolant, 1 | to 21 more than the specified capacity for the vehicle. The fuid tank of the vacuum filer device must be positioned at the same height as the coolant expansion tank. The ‘compressed air connection must have a pressure of 6 bar. Ignition is switched otf hicunea Soma aud Follow notes for repair work on the cooling system. For additional information s Main group 17 17 00 .. Notes for working on the cooling system ‘TECHNICAL INFORMATION Life-long fill of coolant! Do not reuse used coolant. ‘When replacing and removing components which rely on the corrosion protection effect of the coolant, itis essential to change the coolant. The cooling system must therefore be emptied and refiled. Inthe case of other removal work involving the draining of part quantties of coolant, the coolant level must be topped up with new coolant. ‘TECHNICAL INFORMATION Filling without the vacuum filer device (watering can filing) is not permitted, Non-compliance will result in danger of component damage andior engine damage. Fling specifcation absolutely must be adhered to. ‘The operation of the vehicle is not permitted unless the filing procedure has been completed. Otherwise, functional limitations (degradation) and/or overneating may occur. bleeding procedure is required after a part has been exchanged in the cooling system andlor: ‘cooling system. terrefiing the ‘TECHNICAL INFORMATION Make sure that the ignition (terminal 15) is switched off prior to creating the vacuum with the vacuum filer device. > Observe the coolant typeCoolant in the vacuum filer device container cas, a ws 20 ure MINI Diosol W168 3) ‘Choose the correct coolant for fling vehicle must be filed wih the coolant with which itis delivered ex works 1. G48 (Blue) G48 must not be mixed with the I2Coolant or the G30 MINI diesel fuelW16. 2. 13 coolant (blue) is used only for the i heater circuit. 8 coolant must not be filed in the other coolant cicuits or mixed with the other coolants, 3. HT12 (Pink) HT12 must not be mixed with the 13 coolant or the G30 MINI diese! fuel W16. 4. HT12 (Groen) HT12 must not be mixed with the 13 coolant or the G30 MINI diese! uel W16. 5, G30 (Pink) must be used only for the MINI diesel fuel W16, G30 must not be filled in the other coolant circus or mixed with the other coolants, Pons Damage to the engine. ‘The use of an incorrect coolant may lead to corrosion or gelling in the engine. Use only approved coolants for the specific vehicle, Filthe vehicle only with the coolant with which twas delivered ex works. Mix only compatible coolants, The colour does not allow any assessment about the compatibity of coolants. Selection of the correct coolant only by means of the part number.