E46 320d Limousine

BMW SERIES 3
E46
WORKSHOP SERVICE
MANUAL
bavarianmanualsworkshop.com
E46 320d LIMOUSINE INDEX
00 Maintenance and general note 37

00 Maintenance 37
Battery: check display (magic eye); if necessary, recharge battery 37
Battery: checking acid level, topping up with distilled water if necessary. If necessary, recharge battery. 38
BMW engine oil service (M47) 39
BMW engine oil service (M47TU) 41
BMW engine oil service incl. supplementary service (M57 / M47TU) 43
BMW service-inspection (diesel vehicles) 45
Body and underbody: checking for corrosion and damage - except cavities 47
Brake and clutch hydraulic system: checking fluid level, topping up if necessary 48
Brake lines and connections: visual inspection for leaks, damage and correct position 49
Changing brake fluid 50
Changing coolant 51
Changing differential oil 52
Changing engine oil and oil filter 53
Check coolant level, if topping up: checking concentration 54
Check fuel cooler for external contamination, clean if necessary 55
Checking clutch drive plate for wear 56
Checking handbrake lever travel, adjusting according to setting specifications if necessary 57
Checking horn, headlight flashers and hazard warning system 58
Checking instrument and indication field lighting, heater blower 59
Checking lighting system 60
Checking roadworthiness 61
Coolant hoses: Perform visual inspection for tightness, check coolant level and concentration, top up if necessary 62
Description of inspection work 63
Diagnostic brief test 64
Engine oil consumption measurement 65
Exhaust system: checking condition, mounting and inspecting for leaks 67
Fault memory interrogation 68
Front and rear brake linings: checking lining thickness with measuring gauge. If linings are replaced: cleaning brake shafts, checking brake disk thic 69
Fuel cooler: checking for external contamination, cleaning if necessary 70
Fuel lines, fuel tank and fuel hoses: visual inspection for routing, condition and leaks 71
Heating/air conditioning: replacing microfilter/carbon canister (shorten replacement interval accordingly in event of larger buildup of dust) 72
Intake silencer: Renew air filter element (shorten change interval if heavily clogged with dust) 73
Locking systems: checking status and function, oiling or greasing if necessary 74
Oil change in manual transmission 75
Oil change in rear differential 76
Oil change in transfer case 77
Output shafts: checking gaiters for leaks 78
Parking brake: checking function, adjusting/repairing as prescribed 79
Parking brake: checking lining thickness 80
Power steering/ride-height control: visual inspection for leaks, checking fluid level, topping up fluid if necessary 81
Preliminary check prior to general inspection 82
Renew main fuel filter (if necessary, shorten filter-change intervals in case of poor diesel quality) 83
Replacing main fuel filter (shortening change interval if necessary in event of poor diesel fuel quality) 84
Resetting service interval indicator according to factory specifications 85
Seat belts: checking condition of belt strap, function of inertia reel mechanism, locking reel, belt buckle 86
Steering components: checking for zero clearance, leaks, damage and wear 87
Steering fluid reservoir: checking fluid level, topping up if necessary 88
Transmission (all gears): visual inspection for leaks. 89
Tyres: checking inflation pressure, correcting if necessary (incl. spare wheel), checking external condition, tread depth, pattern. In event of nonuni 90
Underbody incl. all visible components: checking for damage, leaks, corrosion 91
Vehicle care measures for inventory vehicles (new and used vehicles) as well as vehicles to be taken off the road that are in the hands of customers 92
When driving on a race track 95
Windscreen wash/wipe system: checking washer fluid reservoir and spray nozzle adjustment 99
Windscreen washer system and intensive cleaning system: checking fluid level, topping up if necessary 100
Work instruction for removing the protective film 101
01 Safety information, note regarding the handling of the repair instructions 102
Danger of poisoning if oil is ingested/absorbed through the skin 102
Information on using cleaning agent/paints (personal protection equipment) 103
Instructions for desiccant insert replacement 105
Notes on handling the high pressure cleaner 106
Risk of injury if oil comes into contact with eyes and skin 108
Safety instructions for handling oil 109
Symbols used and information in repair instructions 110
02 Raise vehicle and tow away 113
Raising the vehicle using a vehicle lift 113
Raising vehicle with trolley jack 115
03 Tightening specifications 116
Microencapsulated screws 116
04 12 V vehicle electrical system 117
Information on intelligent battery sensor (IBS) 117
Notes for disconnecting and connecting battery 118
Notes on AGM battery 120
06 Vehicle-specific notes 124
Information/warning labels 124
Instructions for replacement of air conditioning capacitors and radiator/coolers 127
Notes on handling navigation computers 128
07 Operating fluids 130
Instructions for handling R 134a refrigerant 130
Instructions for handling R1234yf refrigerant 131
Notes on the refrigerant (R134a, R1234yf) and refrigerant oil 132
Safety information for handling refrigerant R1234yf 134
10 Heating/air conditioning system 135
Notes on changing the air conditioning compressor, determining the amount of refrigerant oil (amount of refrigerant oil of new air conditioning compre 139
11 General maintenance 146
Checking/topping up fluid level in automatic transmission (A5S 360R / 390R, A4S 200R / 310R) 146
Checking/topping up oil level in rear differential 147
Notes on SMG transmission service functions 148
Oil change in automatic transmission (A4S 310R / 270R) 150
Oil change in rear differential incl. used oil disposal 154
11 Engine 156
00 Engine 156
BMW engine oil service (M47) 156
BMW engine oil service (M47TU) 158
BMW engine oil service incl. supplementary service (M57 / M47TU) 160
Checking compression in all cylinders (M47 / M57 / M47TU) 162
Engine identification 164
Equipment recoding special tool number of the transverse member for fixing the engine in the installation location 174
Handling components after flood damage 175
Overview of consumables (Electronic Parts Catalogue) 176
Removing and installing engine (M47) 180
Removing and installing engine (M47TU) 184
12 Cylinder head with lid 192
Check cylinder head for watertightness (M47TU / M47T2) 192
Checking a valve guide for wear (M47 / M47TU) 193
Checking cylinder head for water leaks (M47) 194
Cleaning cylinder heat intake channels and intake plenum (M47, M57) 195
Disassembling and assembling cylinder head (M47 / M47TU) 203
Removing and installing cylinder head (M47 / M47TU) 206
Removing and installing cylinder head (M47) 207
Removing and installing cylinder head (M47TU, M47T2) 219
Removing and installing/sealing cylinder head cover (M47) 224
Removing and installing/sealing the cylinder head cover (M47TU / M47T2) 226
Replacing cylinder head gasket (M41 / M47) 228
Replacing cylinder head gasket (M47 /M47TU) 229
Replacing cylinder head gasket (M57 /M47TU) 230
13 Oil sump 231
Removing and installing, sealing / replacing oil sump (M47) 231
Removing and installing, sealing or replacing oil sump (M47) 233
Removing and installing, sealing or replacing oil sump (M47TU) 240
14 Case Covers 244
Removing and installing, sealing/replacing timing case cover at bottom (M47) 244
Removing and installing, sealing/replacing timing case cover at bottom (M47TU / M47T2) 247
Replacing crankshaft radial seal (M47 / M57) 250
Replacing crankshaft radial seal (M47TU / M47TU2) 253
Replacing radial seal in lower timing case cover (M47) 255
Replacing radial seal in timing case cover at bottom (M47TU / M47TU2) 256
21 Crankshaft and Bearings 258
Replacing all crankshaft main bearing shells (M47/M47TU) 258
Replacing crankshaft (M47 / M47TU) 263
Replacing deep-groove ball bearing in crankshaft (M47 / M47TU / M57) 266
22 Flywheel 267
Removing and installing or replacing flywheel (M47 / M47TU) 267
Replacing roller bearing for dual-mass flywheel 269
23 Vibration damper 271
Removing and installing or replacing vibration damper (M47) 271
Removing and installing or replacing vibration damper (M47TU / M47TU2) 273
24 Connecting Rods and Bearings 276
Replacing all conrod bearings (M47 / M47TU) 276
25 Pistons with Rings and Pins 279
Removing and installing or replacing all pistons (M47) 279
Removing and installing or replacing all pistons (M47TU / M47T2) 284
Replacing piston rings on all pistons (M47 / M47TU) 289
27 Counterbalance shafts 290
Removing and installing/replacing balancing shaft housing and balancing shafts 290
28 Drive belt with tensioning and deflecting element 291
Removing and installing A/C compressor belt tensioner (M57 / M47TU) 291
Removing and installing alternator drive belt (M57 / M47TU) 293
Removing and installing/replacing alternator drive belt (M57 / M47TU) 295
Removing and installing/replacing drive belt (elastobelt) for A/C compressor (M47TU / M47T2) 297
Replacing A/C compressor drive belt (M57 / M47TU) 299
Replacing alternator drive belt (M47) 300
Replacing alternator drive belt tensioner (M47) 302
Replacing compressor drive belt for air conditioning (M47) 303
31 Camshaft 304
Adjusting camshaft timing (M47) 304
Adjusting camshaft timing (M47TU) 309
Checking camshaft timing (M47) 313
Checking camshaft timing (M47TU) 314
Removing and installing/replacing hydraulic chain tensioner (M47) 316
Removing and installing/replacing hydraulic chain tensioner (M47TU / M47T2) 317
Replacing both timing chains (M47) 318
Replacing both timing chains (M47TU) 325
Replacing camshafts (M47) 326
Replacing camshafts (M47TU) 338
34 Valves with springs 347
Replacing all valve springs (M47 / M47TU) 347
Replacing all valve stem seals (M47 / M47TU) 348
40 Oil supply 349
Checking engine oil pressure (M47) 349
Checking engine oil pressure (M47TU / M47T2) 352
41 Oil pump with strainer and motor 355
Installing and removing or replacing oil pump (M47) 355
Removing and installing or replacing oil pump (M47TU / M47TU2) 358
42 Oil filters and lines 361
Removing and installing/sealing or replacing complete main flow oil filter (M47) 361
Removing and installing/sealing or replacing complete main flow oil filter (M47TU / M47T2) 365
44 Oil cooler with supply and drain lines 368
Removing and installing, sealing or replacing oil-to-water heat exchanger (M47TU / M47T2) 368
Removing and installing/sealing or replacing oil-water heat exchanger (M47) 371
51 Coolant pump with drive 376
Removing and installing or replacing water pump (M47) 376
Removing and installing/replacing the coolant pump (M47TU/M47TU2/M57TU/M57T2/) 378
52 Fan 380
Removing and installing/replacing fan clutch (M47 / M47TU / M57 / M57TU) 380
53 Thermostat and engine-proof coolant lines 381
Removing and installing or replacing coolant thermostat (M47) 381
Removing and installing or replacing coolant thermostat (M47TU / M47T2) 383
61 Intake manifold 385
Cleaning cylinder heat intake channels and intake plenum (M47, M57) 385
Removing and installing intake air manifold (M47) 393
Removing and installing intake air manifold (M47TU / M47T2) 397
Removing and installing intake air manifold (M47TU) 399
Removing and installing/replacing left pressure pipe (charge air hose) (M47TU / M47T2) 402
Removing and installing/replacing left pressure pipe (charge air hose) (M57TU) 404
Removing and installing/replacing right pressure pipe (charge air hose) 406
62 Exhaust manifold 410
Removing and installing or replacing exhaust turbocharger (M47TU) 410
Removing and installing, sealing/replacing exhaust manifold (M47) 414
Removing and installing, sealing/replacing exhaust manifold (M47TU / M47T2) 417
65 Charger with control 421
Damage on the exhaust turbocharger due to obstructed oil supply lines 421
Removing and installing or replacing exhaust turbocharger (M47TU) 424
Removing and installing, sealing/replacing exhaust manifold (M47TU / M47T2) 428
Test steps in the event of turbocharger damage 432
66 Vacuum pump 433
Removing and installing or replacing vacuum pump (M47) 433
Removing and installing or replacing vacuum pump (M47TU / M47T2 / M57TU / M57T2) 434
71 Exhaust-gas recirculation 436
Removing and installing/replacing exhaust gas recirculation cooler (M47) 436
Removing and installing/replacing exhaust gas recirculation cooler (M57 / M47TU) 439
72 Secondary air system 441
Removing and installing/replacing exhaust gas recirculation cooler (M47) 441
74 Exhaust-gas recirculation valve 444
Layout of vacuum hoses (M47 / M57TU) 444
Layout, vacuum hoses (M47TU) 445
Replacing pressure transducer for EGR valve (M47TU) 446
Replacing pressure transducer for turbocharger (M47TU) 447
Engine 448
Equipment recoding special tool number of the transverse member for fixing the engine in the installation location 448
12 Engine electrical system 449
Instructions for removal and replacement of control units 450
Notes/information on start assistance (jump starting) 453
Safety information on handling hybrid cars 454
Unlocking and disconnecting various plug connections in electrical and hybrid vehicles 456
14 Electronic Shift Units or Control Units 461
Encoding the control unit (DME/DDE) 461
Note on replacing codable/programmable control units 462
Programming the control unit (DME/DDE) 463
Relay assignment, engine wiring harness (M47, M57) 464
21 Preheating relay 465
Removing and installing or replacing glow plug relay (M47, M57) 465
23 Glow plugs 467
Checking all glow plugs (M47, M57) 467
Replacing all glow plugs (M47) 470
Replacing all glow plugs (M57 / M57TU / M47TU / M47T2 / M57T2) 471
31 Alternator with Drive and Mounting Parts 473
Checking alternator and regulator switch 473
Removing and installing/replacing alternator (M47 / M47TU) 476
Removing and installing/replacing alternator mounting block (M57 / M47TU) 479
32 Controller 480
Replacing regulator switch for alternator (M47TU) 480
Replacing voltage regulator (Valeo/Bosch) 482
41 Starter motor with mounting 485
Removing and installing or replacing starter (M47) 486
Removing and installing/replacing starter motor (M47TU) 488
Replacing the engagement solenoid switch 491
42 Starter line 492
Replacing battery positive lead (M47TU) 492
Replacing safety battery terminal (SBK) 494
51 Engine wiring harness 499
Replacing wiring harness section for engine (M47) 499
Replacing wiring harness section for engine (M47TU) 504
Replacing wiring harness section for injectors (M47TU) 509
61 Oil pressure, oil temperature, oil level display 514
Removing and installing/replacing oil level sensor 514
Removing and installing/replacing oil pressure switch (M47) 515
13 Fuel preparation and control 517
31 Fuel pump with drive and line 517
Checking fuel delivery pressure (M47) 517
Checking fuel feed pressure (M47TU) 519
Checking fuel return pressure (M47TU) 521
Layout of common rail system (M47TU / M47TU2) 523
32 Fuel filter 524
Removing and installing/replacing fuel cooler (M47) 524
Renewing fuel preheating 525
Replacing fuel filter (M47) 526
Replacing fuel filter (M47TU / M57TU) 527
Replacing fuel filter unit (M47) 529
Replacing preheating valve (M47TU / M57TU) 530
51 Injection pump, control section, mixture control unit 531
Checking high pressure pump (M47TU / M57TU) 531
Checking injection pump measured value (M47) 533
Fuel metering unit (M47TU/M47T2 / M57TU, M57T2) 536
Removing and installing/replacing high-pressure pump (M47TU, M47T2) 537
Removing and installing/replacing injection pump (M47) 541
Statically adjusting injection pump (M47) 553
53 Fuel Injector Nozzles and Lines 558
Checking injectors (without piezo-technology) with return flow quantity meter 558
Cleaning injector sockets (M67/M57/M57TU/M57T2/M47TU/M47T2) 560
Layout of common rail system (M47TU / M47TU2) 562
Removing and installing/replacing all injector nozzles (M47) 563
Removing and installing/replacing all injectors in fuel injection system (M47TU, M47T2) 565
Removing and installing/replacing pressure accumulator of injection system (M47TU) 568
Removing and installing/replacing pressure sensor on pressure accumulator of injection system (M47TU) 569
Replacing all injection lines (M47) 570
Replacing all leakage oil lines (M47TU, M47T2) 571
Replacing all pressure lines (M57 / M57TU) 573
Replacing pressure line (between high-pressure pump and pressure accumulator) (M57 / M47TU / M57TU / M47T2) 575
61 Electronic control unit 576
Replacing control unit (DDE) for M47 and M57 576
Replacing control unit (DDE) for M47TU 577
62 Senders for Control Unit 578
Removing and installing / replacing pedal travel sensor (M47 / M57) 578
Removing and installing/replacing air-mass flow sensor (M47) 582
Removing and installing/replacing air-mass flow sensor (M47TU) 583
Replacing camshaft pulse generator (M47TU / M57TU / M47T2) 585
Replacing charge-air pressure sensor (M47) 586
Replacing charge-air pressure sensor (M57 / M47TU) 587
Replacing coolant temperature sensor (M47) 588
Replacing crankshaft pulse generator (M47TU / M57TU / M47T2 / M57T2) 590
Replacing speed sensor (pulse generator) (M47) 591
72 Air filter 593
Replacing air cleaner element (M47TU) 593
Replacing air cleaner insert (M47) 595
16 Fuel supply 597
00 Fuel supply 597
Checking filler cap pressure relief valve 597
Checking fuel tank and tank ventilation system for leaks 599
Cleaning complete fuel system (in event of incorrect filling of diesel cars with petrol/gasoline) 602
Draining and filling fuel tank 603
Fuel supply system E46 (diesel engines) 605
Fuel supply system E46 (spark ignition engines) 609
Functional description for general fuel supply systems 615
Layout of fuel supply system (KVA) 616
11 Fuel tank with fuel filler pipe 618
Checking filler cap pressure relief valve 618
Removing and installing / replacing expansion tank for tank ventilation 620
Removing and installing fuel tank 621
Removing and installing/replacing fuel filler pipe 625
12 Lines 627
Removing and installing / replacing activated-carbon filter 627
Removing and installing/replacing carbon canister with LDP (leak diagnosis pump) 628
Removing and installing/replacing diesel pump (supplementary delivery pump) 629
Removing and installing/replacing sensor for fuel gauge (left) (complete unit) 630
Removing and installing/replacing sensor for fuel gauge (right) (complete unit) 633
13 Crankcase ventilation, emission monitoring 635
Removing and installing / replacing activated-carbon filter 635
Removing and installing/replacing carbon canister with LDP (leak diagnosis pump) 636
14 Delivery, preparation and content measurement, control units, electric fuel pump 637
Removing and installing/replacing diesel pump (supplementary delivery pump) 637
Removing and installing/replacing fuel pump (complete sensor unit) 638
Removing and installing/replacing sensor for fuel gauge (left) (complete unit) 639
Removing and installing/replacing sensor for fuel gauge (right) (complete unit) 642
Replacing sucking jet pump 644
Fuel supply 645
17 Cooling 647
00 Cooling, check 647
Checking cooling system for watertightness 647
Checking for leaks between cooling system and combustion chamber 649
Draining and adding coolant (M47, M47TU) 650
Instructions for working on cooling system 654
Venting cooling system and checking for leaks (M47, M47TU) 657
10 Radiator, expansion tank, lines 659
Checking cooling system for watertightness 659
Checking for leaks between cooling system and combustion chamber 661
11 Engine oil cooler and mounting parts 663
Flushing radiator 663
Removing and installing radiator (M47) 665
Removing and installing/replacing coolant expansion tank (M47) 668
Removing and installing/replacing cooling loop for power steering 670
Removing and installing/replacing radiator shutter (M47, M47TU with manual transmission) 672
Removing and installing/replacing vacuum control unit for radiator blind M47 675
Replacing fan cowl (M47 / M47TU) 676
21 Oil cooler 679
51 Charge air cooler with mounting 680
Removing and installing/replacing intercooler (M47, M57) 681
Removing and installing/replacing intercooler (M47TU, M57TU) 683
Cooling 684
Instructions for working on cooling system 684
18 Exhaust system 687
Removing and installing complete exhaust system (M47, M47TU) 687
Removing and installing rear exhaust system (M47, M47TU without primary catalytic converter) 689
Removing and installing/replacing primary catalytic converter (M47, M47TU, M57) 691
Replacing rear muffler bracket on rear axle carrier (repair solution) 693
31 Exhaust pipe with suspension 694
Removing and installing/replacing primary catalytic converter (M47, M47TU, M57) 694
Replacing rear muffler bracket on rear axle carrier (repair solution) 696
21 Clutch 697
00 Clutch, check 697
Bleeding clutch hydraulic system 697
Breaking in SAC clutch 700
21 Clutch Disc and Drive Plate 701
Removing and installing or replacing clutch (SAC 240 /4 cyl. M47TU/T2 only, 6, 8 cyl.) 701
Removing and installing/replacing clutch (SAC 228/4 cyl. without M47TÜ) 712
Replacing roller bearing for dual-mass flywheel 723
51 Clutch release controller w. lever 724
Removing and installing or replacing clutch release bearing/lever 724
52 Clutch operation (hydraulic) 727
Removing and installing or replacing clutch slave cylinder 727
Removing and installing/replacing clutch master cylinder 729
22 Engine and transmission mounting 731
11 Engine mounting 731
Replacing left engine mount (M47, M47TU) 731
Replacing left engine support arm (M47) 733
Replacing left engine support arm (M47TU) 734
Replacing right engine mount (M47, M47TU) 735
Replacing right engine support arm (M43, M47, M47TU, M52) 736
Engine and transmission mounting 737
Replacing left engine mount (M47, M47TU) 737
Replacing left engine support arm (M47) 739
Replacing left engine support arm (M47TU) 740
Replacing right engine mount (M47, M47TU) 741
Replacing right engine support arm (M43, M47, M47TU, M52) 742
23 Manual gearbox 743
Gear train arrangement (S5D 260Z / 310Z / 320Z) 744
Gearshift component arrangement (S5D 260Z / 310Z / 320Z) 749
Housing arrangement, front/rear section (S5D 260Z / 310Z / 320Z) 751
Installing replacement transmission (GS5-39DZ) 752
Installing replacement transmission (GS6-37BZ/DZ) 754
Installing replacement transmission (S5D 310Z / S5D 320Z) 756
Removing and installing transmission (GS5-39DZ, M47TU / M57) 758
Removing and installing transmission (GS6-37BZ/DZ) 765
Removing and installing transmission (S5D 320Z, M47) 771
Transmission arrangement (S5D 260Z / 310Z / 320Z) 779
Transmission arrangement, front section (S5D 260Z / 310Z / 320Z) 782
Transmission arrangement, rear section (S5D 260Z / 310Z / 320Z) 783
Transmission designations 784
Universal BMW transmission take-up 788
Universal transmission retaining bridge 789
11 Housing with cover 790
Replacing bearing bushing for 5th/reverse gear locking pin (C/F transmission) - transmission removed 790
Replacing catch pin (S5D ...Z and GS5-39DZ / C- and F-transmissions) 793
Replacing guide tube for clutch release gear (S5D 310Z/ S5D 320Z) 796
Replacing guide tube for clutch release unit (GS5-39DZ) 797
12 Bearing in housing, sealing ring 798
Replacing drive shaft radial seal (S5D 260Z/ 310Z/ S5D 320Z) 798
Replacing output flange radial seal (S5D 260Z/ 310Z/ S5D 320Z) 800
Replacing radial seal for drive shaft (GS5-39DZ) 802
Replacing radial seal for output flange (GS5-39DZ) 805
Replacing radial seal for selector shaft (GS5-39DZ) 808
Replacing radial seal for selector shaft (S5D 260Z / 310Z / 320Z) 810
Replacing radial shaft seal for drive shaft (GS6-37BZ/DZ) 812
Replacing radial shaft seal for output flange (GS6-37BZ/DZ H-gearbox) 814
Replacing radial shaft seal for selector shaft (GS6-37BZ/DZ H-transmission) 816
21 Transmission shafts 818
Gear train arrangement (S5D 260Z / 310Z / 320Z) 818
Removing and installing complete drive and output shafts (S5D 260Z / 310Z / 320Z) 823
Replacing bearings on all transmission shafts (S5D 260Z / 310Z / 320Z) 841
Replacing output flange for transmission (GS5-39DZ) 846
Replacing output flange for transmission (S5D 310Z / S5D 320Z) 847
23 Synchromesh 848
Disassembling and assembling all synchronizing mechanisms (S5D 260Z / 310Z / 320Z) 848
30 Gearshift 859
Gearshift component arrangement (S5D 260Z / 310Z / 320Z) 859
Replacing catch pin (S5D ...Z and GS5-39DZ / C- and F-transmissions) 864
31 Inner gearshift components 867
Manual gearbox 870
Notes on SMG transmission service functions 870
24 Automatic transmission 878
Adjusting selector lever (A5S 360R / 390R, A4S 200R, 6HP26Z/19Z) 878
Checking/topping up fluid level in automatic transmission (A5S 360R / 390R, A4S 200R / 310R) 879
Removing and installing automatic transmission (A5S 360R / 390R, M47/ M57) 884
Removing and installing automatic transmission (A5S 390R, M47TU) 892
Removing and installing replacement transmission (A5S 360R / 390R, A4S 200R) 898
Removing and installing sealing cap on working piston (A4S 310R) 900
11 Transmission Case, Oil Sump 911
Removing and installing/replacing selector unit (A5S 360R/390R, A4S 200R) 911
Removing and installing/replacing transmission screen (A5S 360R / 390R, A4S 200R) 913
Removing and installing/sealing or replacing transmission fluid sump (A5S 360R / 390R, A4S 200R) 914
12 Torque converter bearing, seal 915
Replacing radial shaft seal for torque converter (A5S 360R / 390R, A4S 200R) 915
13 Transmission Extension, Bearings, Sealing Ring 917
Installing output flange add-on kit (A5S 360R) 917
Removing and installing or replacing transmission extension housing (A5S 360R / 390R) 922
Replacing radial seal for output flange (A5S 360R / 390R) 928
21 Drive/intermediate/output shafts 932
Installing output flange add-on kit (A5S 360R) 932
Replacing output flange (A5S 360R / 390R) 937
30 Electro-hydraulic control parts and elements 940
Removing and installing/replacing selector unit (A5S 360R/390R, A4S 200R) 940
32 Controller 942
Replacing pressure regulator for converter lockup clutch (AS5 360R/390R, A4S 200R) 942
Replacing pressure regulator for main pressure (A5S 360R/390R, A4S 200R) 943
34 Shift valves, parking lock 944
Programming/replacing control unit 944
Replacing pressure regulator for converter lockup clutch (AS5 360R/390R, A4S 200R) 945
Replacing pressure regulator for main pressure (A5S 360R/390R, A4S 200R) 946
Replacing solenoid valve 1, 2 or 3 (A5S 360R / 390R, A4S 200R) 947
35 Wiring harness, shift elements and sensors 948
Replacing pulse generator (output speed) (A5S 360R / 390R, A4S 200R) 949
Replacing pulse generator (turbine speed) (A5S 360R / 390R, A4S 200R) 950
Replacing transmission switch (A5S 360R / 390R, A4S 200R) 951
Replacing wiring harness in automatic transmission (A5S 360R/390R, A4S 200R) 953
40 Torque converter 955
Removing and installing/replacing torque converter (A5S 360R / 390R, A4S 200R) 955
50 Gearshift 957
Replacing radial shaft seal for manual shift valve shaft (A5S 360R / 390R, A4S 200R) 957
52 Internal gearshift 960
Replacing radial shaft seal for manual shift valve shaft (A5S 360R / 390R, A4S 200R) 960
61 Electronic control unit 963
Automatic transmission 965
25 Gearshift 968
11 Centre shift for mechanical transmission 968
Removing and installing shift lever 968
Replacing bearing bushes for shift arm 972
Replacing bearing shell for shift lever 973
Replacing complete shift lever 974
Replacing knob for shift lever 975
Replacing shift arm for shift-lever mount 976
Replacing shift arm support bearing 979
Replacing shift rod 980
Replacing shift rod joint 982
16 Gearshift bracket - Automatic Transmission 984
Adjusting interlock cable 984
Checking/adjusting Interlock/Shiftlock function 987
Removing and installing / replacing shift tower (Steptronic) 989
Removing and installing/replacing interlock cable 993
Removing and installing/replacing shift tower 994
Removing and installing/replacing shiftlock solenoid 998
Removing and installing/replacing shiftlock solenoid (Steptronic) 1001
Replacing cable for gear selector lever 1005
Replacing handle for selector lever 1006
26 Propeller shaft 1007
11 Single or multiple part propeller shaft 1007
Overview of propeller shaft with universal joint 1007
Removing and installing complete propeller shaft (three-piece propeller shaft) 1008
Removing and installing complete propeller shaft - Version with rear constant velocity joint - 1011
Removing and installing propeller shaft (cardan universal joint) completely 1015
Removing and installing/replacing front centring mount for propeller shaft 1019
Replacing flexible disc for propeller shaft 1020
12 Centre console assembly 1021
Replacing both complete propeller shaft center mounts (three-part propeller shaft) 1021
Replacing complete propeller shaft centre bearing (constant-velocity joint) 1026
Replacing complete propeller shaft centre mount 1028
Replacing deep-groove ball bearing in propeller shaft center mount (three-part propeller shaft) 1031
Replacing grooved ball bearing in center mount of propeller shaft 1037
27 Transfer box 1041
31 Front axle, front suspension 1044
00 Front axle in general 1044
Front axle + steering: wheel/chassis alignment check must be carried out after the following work 1045
Front axle overview 1046
Information on replacing shock absorbers 1047
Instructions (chassis components made of aluminium) 1048
Layout of spring strut shock absorber 1049
Mobile table lift 1050
Notes 1052
Notes on repairing threads 1053
Notes on wheel bearing replacement following accident damage 1055
10 Front Axle Suspension 1059
Removing and installing complete front axle (with spring strut shock absorber) 1059
Removing and installing/replacing reinforcement (cruciform) 1060
11 Front axle support 1061
Lowering/raising front axle carrier 1061
Removing and installing/replacing reinforcement (cruciform) 1062
Replacing front axle carrier 1063
12 Wishbones and struts including rubber mounts 1064
Measuring play of wheel control joints 1064
Removing and installing left or right control arm 1067
Removing and installing/replacing both brackets for control arm 1068
Replacing left or right control arm 1072
21 Wheel Bearings and Steering Knuckle 1074
Replacing (removing and installing) left or right steering knuckle 1074
Replacing bearings (wheel hub) for front wheel 1076
31 Spring Struts 1079
Instructions on handling the BMW spring tensioner 1080
Removing and installing complete left or right spring strut shock absorber 1085
Replacing front left or right spring strut shock absorber 1086
33 Spring with mounting 1091
(Removing and installing) replacing front left or right spring strut support bearing 1091
Measuring ride-level height of vehicle 1092
Removing and installing/replacing coil spring for front left or front right spring strut 1093
35 Anti-roll bar 1094
Removing and installing/replacing front stabilizer 1094
Removing and installing/replacing push rod (anti-roll bar link) for left/right anti-roll bar 1095
Replacing rubber mount for stabilizer on body on left or right 1096
60 Output shaft 1097
Notes on removing and installing Low Profile band clamps 1097
Front axle, front suspension 1099
Front axle overview 1099
32 Steering and Wheel Alignment 1102
00 Steering, measurement 1102
Adjusting rear axle 1102
Adjusting toe-in and camber on front axle 1103
Carry out Kinematics Diagnosis System wheel alignment with vehicle load up to design position 1105
Carrying out steering angle sensor adjustment 1108
Front axle + steering: wheel/chassis alignment check must be carried out after the following work 1110
General chassis and suspension definitions 1111
General information and definitions 1112
Identification of suspension without label 1114
Identification on volume production suspension, sports suspension etc. 1115
KDS data statuses 1116
Kinematics Diagnosis System wheel alignment with ride height measurement without loading the vehicle 1117
Moving vehicle into design position 1120
Moving vehicle into normal position 1121
Notes and specifications for the replacement of the steering gear, steering column and the steering shaft following accident damage 1122
Overview of steering 1124
Overview of steering wheel / casing components / lock cylinder 1125
Performing rim runout compensation 1126
Rear axle: wheel/chassis alignment check must be carried out after the following work 1127
Test conditions for chassis/wheel alignment check 1130
11 Mechanical steering gear 1131
Notes on checking steering backlash on vehicles with rack-and-pinion steering (with front axle raised) 1133
Replacing gaiter for steering gear on left or right 1134
13 Steering gear with power steering unit 1135
Bleeding power steering unit 1135
Removing and installing/replacing power steering gear 1138
21 Steering column stalk, track rod, steering damper 1139
Instructions for removing and installing ear clips 1139
Replacing left or right tie rod 1141
31 Steering column 1143
Disassembling and assembling steering column 1143
Removing and installing / replacing lower section of steering column trim 1150
Removing and installing / replacing lower section of steering spindle 1151
Removing and installing steering column 1152
Removing and installing/replacing steering angle sensor 1154
Replacing adjusting lever for steering column 1157
Replacing flexible disc 1159
Replacing steering column 1160
Replacing steering spindle sleeve 1161
Replacing upper section of steering column trim 1163
Replacing upper section of steering spindle 1164
32 Steering lock 1165
Removing and installing/replacing interlock cable 1165
Removing and installing/replacing steering lock cylinder 1166
33 Steering Wheel 1167
Removing and installing/replacing steering wheel 1167
Replacing lower cover for sport steering wheel 1168
34 Airbag and airbag steering wheel 1169
Notes on scrapping BMW vehicles with gas generators (airbag system) 1169
Notes on scrapping BMW vehicles with gas generators (central airbag control unit, airbag system) 1173
Procedure after airbag deployment as result of an accident 1175
Removing and installing/replacing airbag unit 1178
Removing and installing/replacing the airbag unit (sports steering wheel, inserted airbag unit) 1180
Safety regulations for handling airbag system components 1183
Safety regulations for handling components with gas generators 1185
41 Pump and Oil Supply 1187
Bleeding power steering unit 1187
Instructions for removing and installing ear clips 1188
Instructions for using special tool 32 4 000 1190
Notes on hydraulic line with quick-connect coupling 1192
Removing and installing or replacing oil cooler/cooling coil for power steering 1194
Removing and installing power steering vane pump (M47) 1195
Removing and installing vane pump for power steering (M47TU) 1197
Removing and installing/replacing belt pulley on vane pump for power steering 1199
Replacing power steering vane pump 1200
Steering and Wheel Alignment 1201
Overview of steering 1202
Overview of steering wheel / casing components / lock cylinder 1203
Test conditions for chassis/wheel alignment check 1204
33 Rear axle, rear-wheel drive, guide 1205
Instructions (chassis components made of aluminium) 1207
Layout of fuel supply system (KVA) 1208
Notes on wheel bearing replacement following accident damage 1211
Overview of control arms with rubber mounts 1212
Overview of final drive/output shafts 1213
Overview of rear axle carrier with rubber mounts 1214
Rear axle layout 1216
Rear axle: wheel/chassis alignment check must be carried out after the following work 1217
10 Rear axle final drive 1220
Checking/topping up oil level in rear differential 1220
Oil change in rear differential incl. used oil disposal 1221
Rear differential: Assignment to model series 1223
Removing and installing/replacing rear differential 1224
11 Transmission housing with lid 1227
Removing and installing/replacing vibration damper 1227
Replace the radial shaft seal for the left or right drive flange 1228
Replacing drive flange on left or right of final drive 1230
Replacing rear cover gasket on rear differential 1231
Replacing rear cover gasket on rear differential (168K) 1232
Replacing shaft seal for input flange on final drive 1235
None 1238
17 Rear axle differential mountings 1241
Replacing all rubber mounts for front final drive suspension 1241
Replacing rubber mount for final drive mounting at rear 1242
21 Output Shaft 1244
Pressing output shaft out of drive flange and drawing in (output shaft removed from rear axle final drive) 1244
Removing and installing / replacing left output shaft 1247
Removing and installing / replacing right output shaft 1248
Removing and installing/replacing left or right output shaft 1249
Ribbed teeth 1250
31 Rear axle support 1251
Lowering/raising rear axle carrier 1251
Removing and installing complete rear axle carrier 1253
Replacing rear axle carrier 1256
32 Trailing arms and struts 1257
Overview of control arms with rubber mounts 1257
Removing and installing / replacing tension strut for rear axle carrier 1258
Removing and installing complete left or right trailing arm 1259
Removing and installing/replacing lower wishbone arm 1261
Replacing a rubber mount in trailing arm, front 1263
Replacing a rubber mount/ball joint in the trailing arm for bottom wishbone 1266
Replacing bearing block for front trailing arm 1268
Replacing both eccentric bolts 1270
Replacing left or right trailing arm 1271
Replacing one ball joint in the semi-trailing arm (semi-trailing arm removed) 1272
Replacing one rubber mount in lower control arm (control arm removed) 1273
Replacing one rubber mount in the upper control arm (control arm removed) 1274
Replacing one upper control arm 1275
33 Rear Axle Suspension 1276
Replacing two additional rubber mounts for rear axle carrier (rubber mount at rear) 1276
Replacing two rubber mounts for rear axle carrier (rubber mounts, front) 1278
41 Wheel Bearings 1280
Detaching wheel bearing inner race from drive flange (drive flange removed) 1280
Replacing drive flange on left/right rear axle shaft 1281
Replacing wheel bearing (75 mm) on rear axle shaft on left or right 1283
Replacing wheel bearing (85 mm) on rear axle shaft on left or right 1285
52 Shock Absorbers 1287
Removing and installing/replacing rear left or right shock absorber 1288
Replacing rear left or right thrust bearing for spring strut/shock absorber 1290
53 Springs with suspension 1291
Measuring ride-level height of vehicle 1291
Removing and installing / replacing rear left or right coil spring 1292
Removing and installing / replacing rear stabilizer 1295
Removing and installing / replacing rear stabilizer bar 1296
Replacing anti-roll bar links for anti-roll bar 1298
Replacing anti-roll bar links for stabilizer bar 1299
Replacing both rubber mounts for stabilizer mounting 1300
Rear axle, rear-wheel drive, guide 1301
34 Brakes 1302
00 Braking, check, ventilation 1302
Bleeding brake system with ABS/ASC+T 1302
Bleeding brake system with DSC3 1304
Checking brakes on test stand 1306
Checking parking brake setting (for inspection) 1307
Checking service brake: high- and low-pressure tests 1308
Checking thickness of brake lining 1309
General Data 1310
General information on braking in new brake discs / brake pads 1312
Guideline for applying brake pad paste on brake pads and caliper carrier 1313
Parking brake function check 1326
Replacing fluid in ABS/ASC+T brake system 1327
11 Front Wheel Brakes 1329
Configuration of floating caliper (front) 1329
Overhauling left or right front brake caliper (brake caliper removed) 1330
Overhauling left or right front-brake caliper (brake caliper removed) 1332
Precision-turning both front brake discs on both sides (brake disc removed) 1335
Removing and installing/replacing a front brake anchor plate/brake guard plate 1336
Removing and installing/replacing both front brake discs 1337
Removing and installing/replacing brake pads of both front disc brakes 1339
Removing and installing/replacing left or right front brake caliper 1344
21 Rear Wheel Brakes: 1345
Fine-grinding both sides of both rear brake disks (brake disks removed) 1345
Guideline for applying brake pad paste on brake pads and caliper carrier 1346
Layout of floating caliper (rear) 1359
Overhauling left or right rear brake caliper (brake caliper removed) 1360
Removing and installing/replacing a brake carrier/brake guard at rear 1363
Removing and installing/replacing both brake discs 1364
Removing and installing/replacing both rear brake pads of disc brake 1366
Removing and installing/replacing left or right rear brake caliper 1371
31 Foot and tandem brake master cylinder 1372
Removing and installing / replacing master brake cylinder for DSC 1372
Removing and installing / replacing the master brake cylinder 1374
Removing and installing/replacing brake master cylinder for DSC (MK60) 1376
Removing and installing/replacing expansion tank for hydraulic brake actuation 1377
32 Brake Lines 1378
Replacing all brake pipes 1378
Replacing both rear brake hoses 1379
Replacing front left or right brake hoses 1381
33 Brake servo 1383
Removing and installing/replacing brake booster 1383
Removing and installing/replacing brake unit (MK60) 1384
Removing and installing/replacing non-return valve for brake unit M47 1386
Replacing vacuum hose for brake unit M47 1387
41 Parking brake 1388
Adjusting handbrake 1388
General information on braking in new brake discs / brake pads 1391
Removing and installing/renewing all parking brake pads 1392
Removing and installing/replacing both handbrake bowden cables 1393
Removing and installing/replacing brake shoe expander for handbrake shoes 1395
Removing and installing/replacing handbrake lever 1396
51 Mechanical hydraulic components 1397
Removing and installing / replacing hydraulic unit ABS/ASC+T 1397
Removing and installing pre-boost pump DSC3 1400
Removing and installing/replacing DSC hydraulic unit 1402
Removing and installing/replacing DSC hydraulic unit (MK60) 1404
52 Electronic components 1405
Removing and installing/replacing ABS front pulse generator (MK60) 1405
Removing and installing/replacing control unit for ABS/ASC+T 1406
Removing and installing/replacing control unit for DSC 1407
Removing and installing/replacing control unit for DSC (MK60) 1408
Removing and installing/replacing DSC angular rate sensor 1409
Removing and installing/replacing front pulse generator 1411
Removing and installing/replacing pressure sensor "H" for DSC 1412
Removing and installing/replacing pressure sensor "V" for DSC 1414
Replacing a rear pulse generator 1416
Brakes 1418
35 Pedals 1421
11 Pedal Assembly Console 1421
Removing and installing mounting block for pedals 1421
21 Foot brake lever, connecting linkage 1422
Removing and installing or replacing clutch pedal 1422
Removing and installing/replacing brake pedal 1423
31 Clutch pedal including connecting linkage 1426
Removing and installing or replacing clutch pedal 1426
40 Accelerator pedal activation 1427
Removing and installing/replacing accelerator pedal module 1427
Replacing adapter plate 1428
41 Kick-down 1429
Removing and installing/replacing accelerator pedal 1429
Removing and installing/replacing accelerator pedal module 1432
Removing and installing/replacing bracket for accelerator pedal 1433
Replacing adapter plate 1435
36 Wheels with tyres 1436
10 Wheels 1436
Checking front and rear wheel for face and radial runout 1436
Checking one road wheel on balancing machine for face and radial runout (wheel removed) 1438
Checking rim for face and radial runout 1440
Notes and specifications for tyre / wheel exchange 1442
Remove or install front or rear wheel 1443
Stationary wheel balancing 1446
11 Disc wheels (rims) 1448
Checking rim for face and radial runout 1448
General Information, Series light alloy disk wheel E 46 1450
Removing and installing / replacing RDC wheel electronics 1451
Removing and installing/replacing front receiving antenna for RDC 1454
Removing and installing/replacing RDC control unit 1455
Removing and installing/replacing rear receiving antenna for RDC 1456
12 Tyres 1457
Changing a tyre (on front, rear or spare wheel) 1457
13 Mounting 1462
Subsequent installation of wheel-bolt lock 1462
Wheels with tyres 1463
37 Integrated Suspension Systems 1464
00 Integrated suspension system in general 1464
14 Electric components 1467
Replacing front ride level sensor 1467
Replacing rear ride-height sensor 1468
41 Body 1469
00 Body 1469
0 Contents of Body, General 1469
0 Notes on the repair technique used in the main group 41 1471
Arranging shaped parts for cavity bulkhead 1472
Basic comments on handling aluminium components 1474
Blind rivet 1476
Bonding on painted/primed surfaces 1477
Bonding steel on steel 1479
Corrosion protection 1480
EMC screws 1482
Fix bolts on the new part 1483
Frame alignment control dimensions, body, side view, BMW E 46 4-door / 2-door / Touring / Convertible 1485
Frame alignment control dimensions, body, side view, front end, BMW E 46 4-door / 2-door / Touring / Convertible 1486
Frame alignment control dimensions, body, side view, rear end, BMW E 46 4-door / 2-door / Touring / Convertible 1487
Frame alignment control dimensions, body, top view, BMW E 46 4-door / 2-door / Touring / Convertible 1488
Frame alignment control dimensions, body, top view, front end, BMW E 46 4-door / 2-door / Touring / Convertible 1489
Frame alignment control dimensions, body, top view, rear end, BMW E 46 4-door / 2-door / Touring / Convertible 1490
Gap dimensions on doors / engine hood and trunk lid 1491
General information about body repair 1494
General instructions on paintwork 1496
General notes for labelling with adhesive films 1497
General notes regarding bonding 1499
Gluing of body components 1500
Grinding aluminium components 1501
Grinding steel parts 1502
Handling airbags and restraint systems 1503
Handling electrical system and electronics 1505
Information on hazards 1506
Information on metal filler 1507
Information on vehicle protection 1510
Installation of a cavity seal with cavity foam 1512
Installation solution for straight shank/hexagon rivet nut 1514
Installing a cavity sealing with 2-component PU cavity foam 1516
Installing cavity bulkhead cover for side member 1520
Installing cavity sealing (expanded) 1522
Installing cavity sealing (not expanded) 1523
Installing shaped parts for cavity bulkheads, except for cover for side member 1524
Materials science 1528
Notes on adhesive K1 1532
Notes on aluminum driveline components 1541
Notes on cleaning agent R1 1542
Notes on repairs of aluminium parts 1546
Notes on the water drain hose of the slide/tilt sunroof 1548
Notes on using temperature-controlled infra-red radiators 1549
Opening bonded connections 1550
Opening brazed connections 1551
Opening rivet connections 1552
Opening welded connections 1553
Overview of adhesive cartridge guns 1554
Punch rivets 1560
Quality standard 1561
Recommended working methods and tools 1562
Releasing bonded folded seam connections 1564
Removal of PVC material in repair area 1565
Repair methods, repair stages 1 1566
Repair solution for straight shank/hexagon rivet nut 1567
Repair techniques, repair stage 2 1570
Repair techniques, repair stage 3 1571
Repairing headlights 1572
Repairing plastic components 1573
Replacing blind rivets 1574
Riveting steel components 1577
Safety at work 1578
Safety instructions for handling magnets 1580
Setting blind rivet nuts and bolts 1581
Spot-weld bonding steel components 1582
Spray gun for cavity sealant 1583
Stamping vehicle identification number 1585
Straightening aluminium components 1586
Straightening steel components 1587
Touching up paintwork damage 1588
Use of materials in outer skin 1589
Welding and soldering steel components 1591
Welding in reinforcement plate (sheet steel) 1593
Welding of galvanized plates 1595
Window and door seams E46, 4-door 1596
Working with 2-component PU cavity foam 1598
Workshop equipment (BMW and MINI vehicles) 1599
11 Support 1602
Replacing cover for side member, left or right (partial replacement, B-pillar before A-pillar and side panel, rear) (from 04 / 99) 1607
Replacing cover for side member, left or right (partial replacement, B-pillar before A-pillar and side panel, rear) (up to 04 / 99) 1625
Replacing engine support front section on left (E46) 1642
Replacing engine support front section on right 1644
Replacing right engine support (partial replacement in front of front axle) (E46) 1660
12 Floor panels 1662
Replacing complete rear luggage compartment floor (tail panel removed) (E46) 1663
14 Wheel arches 1669
Replacing complete rear left wheel arch 1678
Replacing engine support side frame connection, front left 1694
Replacing front right wheel arch 1695
Replacing outer section of left or right rear wheel housing (side panel removed) 1702
21 Side frames and pillars 1715
Replacing front left door column (partial replacement) (front side panel removed) 1726
Replacing left or right cowl panel (partial replacement in front of roof connection) 1739
22 Roof frame 1752
31 Roof 1761
Replacing roof panel (models with slide/tilt sunroof) 1770
32 Front and rear window frame 1771
Replacing left or right cowl panel (partial replacement in front of roof connection) 1780
33 Front trim panel 1787
Replacing front left or right side wall holder 1788
34 Rear trim panel 1791
Replacing tail panel (E46) 1792
35 Side Panels 1796
Removing and installing or replacing left or right front side panel 1805
Replacing front left or right side wall holder 1808
Replacing rear left side panel (partial replacement, C-pillar)(E46 saloon/sedan) 1817
51 Front doors 1828
Adjusting left or right front door 1828
Adjusting left or right rear door 1832
Notes on replacing the door 1836
52 Rear doors 1837
Adjusting left or right rear door 1837
Notes on replacing the door 1841
61 Engine compartment lid 1842
Aligning hood lid 1842
62 Tailgate 1850
Adjusting trunk lid to fit 1850
Body 1857
51 Body equipment 1860
00 General body equipment 1860
Notes on component bonding with adhesive tape 1862
Notes on installing rubber window seals 1863
Safety information for working on vehicles with airbag systems 1868
Service position of engine compartment lid 1869
11 Front Bumper 1871
Checking shock absorber (impact absorber) for front bumper 1871
Installing/replacing license plate (without base) 1872
Removing and installing complete front bumper (from 10/01) 1873
Removing and installing complete front bumper (up to 9/01) 1876
Removing and installing/replacing trim grill for bumper trim (up to 9/01) 1878
Replacing a shock absorber (impact absorber) for front bumper 1879
Replacing baseplate for license plate 1880
Replacing body molding for left or right bumper 1881
Replacing bracket for front left or right bumper (saloon/sedan and touring from 10/01) 1882
Replacing bracket for front left or right bumper (saloon/sedan and touring up to 9/01) 1884
Replacing front bumper (from 10/01) 1885
Replacing front bumper (up to 9/01) 1887
Replacing front bumper trim 1889
Replacing front center section (carrier) of bumper 1890
12 Rear bumper 1891
Checking shock (impact) absorber for rear bumper 1891
Completely removing and installing (from 09.01) bumper 1892
Removing and installing complete rear bumper 1895
Removing and installing/replacing finisher strip on bumper trim 1898
Removing and installing/replacing guide for rear centre bumper (from 09/01) 1899
Replace center section of rear bumper (support beam) 1900
Replace rear bumper trim 1901
Replacing all protective strips for rear bumper 1902
Replacing bracket for rear bumper at left or right 1903
Replacing bracket for rear bumper at left or right (starting 9/01) 1904
Replacing central body molding on rear bumper 1905
Replacing left or right side molding for rear bumper 1906
Replacing one shock absorber for rear bumper 1908
Replacing rear bumper 1910
13 Trim Parts, Covers, Handle Strip 1911
Removing and installing handle strip (on trunk lid) 1911
Removing and installing trim strip on roof frame at left or right 1912
Removing and installing/replacing cowl panel cover 1913
Removing and installing/replacing front radiator grill, middle left or right 1914
Removing and installing / replacing trim cover on left or right headlight housing (Saloon, Touring) 1916
Removing and installing/replacing trim strip on roof gutter at left or right 1917
Replacing bracket for roof luggage rack on left or right 1920
Replacing handle strip (on trunk lid) 1921
Replacing trim strip on roof frame at left or right 1923
14 Badges, labels, adhesive strips 1926
General notes for labelling with adhesive films 1926
Instructions for attaching number/letter designation combination 1928
Removing and installing/replacing front BMW badge 1929
Removing and installing/replacing rear BMW badge 1930
Removing and installing/replacing rear model designation 1931
15 Bumper strip 1934
Removing and installing or replacing body molding on left or right front door 1934
Removing and installing rubbing strip on rear door on left or right 1935
16 Mirrors, Finishers, Ashtrays, Consoles 1936
Disassembling and assembling lock barrel (lock barrel removed) 1936
Gluing of mirror base 1938
Removing and installing / replacing finisher for preselector lever 1940
Removing and installing / replacing interior rearview mirror (with remote control) 1942
Removing and installing center armrest 1943
Removing and installing left glove box 1944
Removing and installing or replacing front grab handle 1945
Removing and installing or replacing sun visor and left or right counter support 1946
Removing and installing right glove box 1947
Removing and installing storage tray 1948
Removing and installing/renewing inside mirror (with Japanese inside mirror with electronic toll function) 1951
Removing and installing/replacing carrier in storage tray 1954
Removing and installing/replacing finisher for storage tray 1957
Removing and installing/replacing front cup holder 1958
Removing and installing/replacing glovebox lock 1960
Removing and installing/replacing insert in storage tray 1961
Removing and installing/replacing inside mirror (with cable ·X· and connector cover) 1963
Removing and installing/replacing inside mirror (with full base) 1965
Removing and installing/replacing inside mirror (with mirror arm end caps) 1966
Removing and installing/replacing inside mirror (with rain sensor) 1969
Removing and installing/replacing interior rearview mirror (overview) 1972
Removing and installing/replacing rear left/right grab handle 1974
Removing and installing/replacing rear-view mirror on left or right front door 1975
Replacing a clipped cover (decorative strip on front or rear door) (Saloon, Touring) 1976
Replacing a clipped-in trim (decorative strip on panel for instrument panel, front or rear door) 1979
Replacing left or right outside mirror housing 1984
Replacing mirror glass for rear-view mirror (on front door) 1985
Replacing right glovebox 1986
Replacing storage tray 1987
17 Flaps 1988
Removing and installing/replacing bump stop with ejector for filler flap 1988
20 Lock cylinders, assembly 1989
21 Door locks, handles, fittings, front 1991
Adjusting front left or right door detent (lock wedge) 1991
Blocking, if necessary initialising, car key in immobiliser control module 1992
Removing and installing cover on outside handle with locking cylinder 1995
Removing and installing or replacing door stop on left or right front door 1996
Removing and installing or replacing window cavity cover strip on outside of left or right front door 1997
Removing and installing/replacing complete lock cylinder in left or right front door 1998
Removing and installing/replacing cover on outside handle 2000
Removing and installing/replacing door lock in left or right front door (from 09/00) 2001
Removing and installing/replacing door lock in left or right front door (to 09/00) 2006
Removing and installing/replacing outer door handle of left or right front door (09/00 and later) 2010
Removing and installing/replacing outside handle and lock actuation of left or right front door (starting 09/00) 2014
Removing and installing/replacing outside handle and lock actuator on left or right front door (up to 09/00) 2017
Removing and installing/replacing outside handle on left or right front door (up to 09/00) 2018
Removing and installing/replacing window cavity cover strip on inner front door 2022
Removing weather strip with special tool 00 9 324 at front or rear 2023
Replacing cover on outside handle with locking cylinder 2024
Replacing door detent (lock striker), front left or right 2025
Replacing locks for simultaneous closing 2026
Replacing locks for simultaneous closing with EWS control module 2027
22 Door locks, handles, fittings, rear 2028
Adjusting rear left or right door lock striker 2028
Removing and installing/replacing cover on outside handle, left or right 2029
Removing and installing/replacing door lock in left or right rear door (from 09/00) 2030
Removing and installing/replacing door lock in left or right rear door (up to 09/00) 2034
Removing and installing/replacing door stop on rear left or right door 2038
Removing and installing/replacing outer door handle in left or right rear door (up to 09/00) 2040
Removing and installing/replacing outside handle and lock actuation of rear door (from 09/00) 2044
Removing and installing/replacing outside handle and lock activator of rear door left and right (up to 09/00) 2046
Removing and installing/replacing outer door handle in left or right rear door (from 09/00) 2047
Removing and installing/replacing window cavity cover strip on inside rear door 2050
Removing and installing/replacing window cavity cover strip on rear door on left or right 2051
Replacing door detent (lock striker), rear left or right 2052
23 Bonnet catch, locks 2053
Adjusting/replacing bump stops 2053
Removing and installing/replacing left or right gas pressure spring for engine compartment lid 2056
Removing/installing ball sockets with clip 2057
24 Tailgate catch, locks 2058
Adjusting/replacing bump stops 2058
Removing and installing/replacing button for rear lid actuation 2060
Removing and installing/replacing lock (lock cylinder) for rear lid 2061
Removing and installing/replacing rear lid lock (upper section) 2064
Removing and installing/replacing striker for rear lid lock 2066
Removing and installing/replacing trim on shaft bearing for rear window wiper 2067
31 Front and rear window 2068
General procedure for the disassembly and installation of bonded window glass 2068
Materials for bonding window 2073
Notes on window bonding 2075
Notes on window bonding repair kit 2076
Overview, rain sensor (additional work when replacing the windscreen / sensor replacement) 2079
Remove windscreen with "Roll Out 2000" 2084
Removing and installing front windscreen 2089
Removing and installing rear window 2093
Removing and installing/replacing rubber frame for windshield (top/side) 2100
Removing windows with a "Spider" 2101
Removing windows with an oscillating knife 2106
Repairing damage to windscreens caused by stone chips (clear and tinted laminated safety glass) 2108
Replacing rear window (rear window broken) 2109
Window glass removal with wire pull handle 2110
32 Power windows, manual operation, front 2112
Adjusting left or right front door window 2112
Removing and installing/replacing cover (anti-trapping protection) on door window frame, left or right, inside 2113
Removing and installing/replacing door window glass, front left or right 2115
Removing and installing/replacing finisher on front door window frame, left or right 2117
Replacing front left or right rubber guide for left or right door window 2119
33 Power windows, electrical operation, front 2120
Removing and installing electric window regulator in left or right front door 2120
34 Power windows, manual operation, rear 2122
Removing and installing/replacing cover (trapping protection) on door window frame (rear door), inside left or right 2122
Removing and installing/replacing trim on window frame of rear door (front), left or right 2123
Removing and installing/replacing trim on window frame of rear door (rear), left or right 2125
Removing and installing/replacing window crank, rear left or right 2127
Replacing left or right fixed door window in rear window frame 2128
Replacing rear left or right door window 2132
Replacing rubber guide for rear left or right door window 2134
35 Power windows, electrical operation, rear 2135
Removing and installing complete power window lifter from rear left and right sides 2135
Replacing left or right fixed door window in rear window frame 2136
37 Side window, body, electrically operated 2140
Notes on window bonding 2140
Removing and installing complete power window lifter from rear left and right sides 2141
41 Front door trim panel with armrests 2142
Creating opening for HiFi speaker. 2142
Notes for bonding sound insulation (SI), doors 2143
Removing and installing left or right front door trim panel 2145
Removing and installing/replacing sound insulation in front door, left or right 2148
Replacing front left or right door trim 2151
42 Rear door trim panel with armrests 2152
Creating opening for HiFi speaker (or window crank) 2152
Creating opening for window crank 2154
Removing and installing rear left or right door trim panel 2157
Removing and installing/replacing sound insulation in rear door, left or right 2160
Replacing left or right rear door trim 2163
43 Side Trim Panel with Armrests 2164
Removing and installing / replacing trim panel for left or right rear roof pillar (C-pillar) 2164
Removing and installing or replacing trim for front left or right roof 2165
Removing and installing or replacing trim for left or right door pillar (bottom) 2166
Removing and installing or replacing trim on left or right door pillar (top) 2167
Removing and installing/replacing side trim panel, footwell, on A-pillar, left 2169
Removing and installing/replacing side trim panel, footwell, on A-pillar, right 2170
44 Headlining 2171
Removing and installing / replacing headliner (with slide/tilt sunroof) 2171
Removing and installing/replacing headliner (without slide/tilt sunroof) 2175
45 Trim, instrument trim panel 2176
Removing and installing instrument panel trim 2176
Removing and installing/replacing trim for pedal assembly 2180
Replacing instrument panel trim 2181
46 Trim panel, rear window storage shelf, roller sunblind 2184
Removing and installing trim for oddments tray (back shelf with rear window roller blind and through-loading system) 2184
Removing and installing trim for oddments tray (back shelf with rear window roller blind) 2185
Removing and installing/replacing finisher for top of rear apron 2186
Removing and installing/replacing rear window roller blind 2188
Removing and installing/replacing rear window roller blind (with through-loading system) 2189
Removing and installing/replacing trim for oddments tray (back shelf with through-loading system) 2190
Removing and installing/replacing trim for rear parcel shelf 2191
Replacing trim for oddments tray (back shelf with rear window roller blind and through-loading system) 2193
47 Floor/luggage compartment/engine compartment, trim panel 2194
Removing and installing / replacing the rear (inside) left or right rocker panel strip 2194
Removing and installing/replacing finishing strip at front left or right entrance 2196
Removing and installing/replacing finishing strip on entrance, rear left or right 2197
Removing and installing/replacing front (inside) left or right entrance cover strip 2198
Removing and installing/replacing luggage compartment floor trim panel 2199
Removing and installing/replacing right trunk wheel arch trim 2200
Removing and installing/replacing trunk wheel housing trim, left 2202
48 Front lid insulation lining 2204
Removing and installing/replacing sound insulation in front door, left or right 2206
Removing and installing/replacing sound insulation in rear door, left or right 2209
49 Tailgate trim panel 2212
Removing and installing or replacing trim for trunk lid 2212
71 Gaskets and loose body components 2213
Attaching seal on front and rear doors, left or right 2213
Removing and installing or replacing panel for cover on left or right side member 2217
Removing and installing/replacing cowl panel cover 2219
Removing and installing/replacing heater bulkhead 2220
Removing and installing/replacing rear left or right wheel arch cover 2222
Removing and installing/replacing reinforcement plate on front axle support 2223
Removing and installing/replacing seal on front door, left or right 2225
Removing and installing/replacing seal on rear door, left or right 2229
Sealing installation 2233
72 Mucket for doors 2235
Sealing installation 2235
52 Seats and motorcycle seat 2237
13 Front seat, normal, manual 2237
Removing and installing / replacing back-rest frame on left or right front seat (normal / manual). 2237
Removing and installing / replacing controls on left / right front seat (normal / manual) 2238
Removing and installing / replacing front headrest (normal/ manual) 2244
Removing and installing / replacing inner cover on left or right front seat backrest (normal/ manual) 2245
Removing and installing / replacing outer cover on left or right front seat back-rest (normal / manual) 2246
Removing and installing / replacing rear panel on left or right front seat backrest (normal/manual) 2248
Removing and installing / replacing valve housing for left or right lumbar support, front (normal / manual) 2250
Removing and installing left or right front seat (normal/manual) 2252
Removing and installing/replacing backrest frame on left or right front seat (sport/manual) 2254
Removing and installing/replacing guide for front left or right head restraint 2256
Removing and installing/replacing seat angle adjuster (normal/manual) on left or right front seat 2258
Removing and installing/replacing seat mechanism (on front seat normal/manual), left or right 2259
Removing and installing/replacing seat pan and flex mat on front left or right seat (sports/electric) 2260
Removing and installing/replacing seat pan and flexmat (normal/manual), left or right 2263
Replacing back-rest cover for left or right front seat (normal / manual) 2265
Replacing left or right support for front seat (normal / manual) 2269
Replacing left or right support for front seat back-rest (normal / manual) 2270
Replacing lumbar cushion on front left or right seat 2271
Replacing seat and backrest covers for front seat (normal/manual), left or right 2273
Replacing seat cover on left or right front seat (normal/manual) 2274
14 Front seat, normal, electric 2281
Additional work (normal/ electric) with defective drive for longitudinal adjustment 2281
Removing and installing / replacing rear panel on left or right front seat backrest (normal / electric) 2284
Removing and installing left or right front seat (normal/electric) 2286
Removing and installing or replacing front left or right head restraints (normal/electric) 2288
Removing and installing or replacing front left or right head restraints (standard/electric) 2289
Removing and installing/replacing backrest frame on front left or right seat (normal/electric) 2290
Removing and installing/replacing carrier for outer cover on left or right front seat (sports/electric) 2291
Removing and installing/replacing guide for front left or right head restraint (normal/electric) 2292
Removing and installing/replacing inner cover on front left or right seat (normal/electric) 2294
Removing and installing/replacing outer cover on front left or right seat (normal/electric) 2295
Removing and installing/replacing seat angle adjuster on left or right front seat (normal/electric) 2296
Removing and installing/replacing seat mechanism on left or right front seat (normal/electric) 2297
Removing and installing/replacing seat pan and flexmat (normal/manual), left or right 2298
Removing and installing/replacing valve housing for front left or right lumbar support (normal/electric) 2300
Replacing backrest cover for front left or right seat (normal/electric) 2301
Replacing lumbar cushion on front left or right seat (normal/electric) 2302
Replacing padding for left or right front seat backrest (normal/electric) 2303
Replacing seat cover for left or right front seat (normal/electric) 2304
Replacing support for left or right front seat (normal/electric) 2305
15 Front seat, sports, manual 2306
Removing and installing front seat (sports/manual), left or right 2306
Removing and installing or replacing front left or right head restraints (sports/manual) 2307
Removing and installing/replacing actuating unit on front left or right seat (sports/manual) 2308
Removing and installing/replacing backrest frame on left or right front seat (sport/manual) 2309
Removing and installing/replacing front left or right head restraints (sports/manual) 2311
Removing and installing/replacing guide for front left or right head restraint (sports/normal) 2312
Removing and installing/replacing holder for thigh support on front seat, left or right (sports/manual) 2313
Removing and installing/replacing inner cover on front left or right seat (sports/manual) 2314
Removing and installing/replacing outer cover on front left or right seat (sports/manual) 2315
Removing and installing/replacing rear panel on front left or right seat backrest (sports/manual) 2316
Removing and installing/replacing seat angle adjuster (sport/manual) on left or right front seat 2318
Removing and installing/replacing seat mechanism on left or right front seat (sport/manual) 2319
Replacing backrest cover for left or right front seat (sport/manual) 2320
Replacing lumbar cushion on front left or right seat (sports/manual) 2321
Replacing padding for left or right front seat (sport/manual) 2322
Replacing padding for left or right front seat backrest (sport/manual) 2323
Replacing seat cover for left or right front seat (sport/manual) 2324
16 Front seat, sports, electric 2325
Additional work (normal/ electric) with defective drive for longitudinal adjustment 2325
Removing and installing front seat (sports/electric), left or right 2328
Removing and installing or replacing front left or right head restraints (sport/electric) 2329
Removing and installing/replacing backrest frame on left or right front seat (sport/electric) 2330
Removing and installing/replacing carrier for outer cover on left or right front seat (sports/electric) 2331
Removing and installing/replacing front head restraint (sports/electric) on left or right 2332
Removing and installing/replacing guide for front left or right head restraint (sports/electric) 2333
Removing and installing/replacing inner cover on front left or right seat (sports/electric) 2334
Removing and installing/replacing left or right seat mechanism (on sport/electric front seat) 2335
Removing and installing/replacing lumbar cushion on front left or right seat (sports/electric) 2336
Removing and installing/replacing outer cover on front left or right seat (sports/electric) 2337
Removing and installing/replacing rear panel on front left or right seat backrest (sports/electric) 2340
Removing and installing/replacing seat angle adjuster on left or right front seat (sport/electric) 2341
Removing and installing/replacing seat pan and flex mat on front left or right seat (sports/electric) 2342
Removing and installing/replacing thigh support holder on front seat, left or right (sports/electric) 2345
Replacing backrest cover on front left or right seat (sports/electric) 2347
Replacing padding for left or right front seat backrest (sport/electric) 2352
Replacing seat cover for left or right front seat (sports/electric) 2353
Replacing support for left or right front seat (sport/electric) 2362
24 Rear seat, normal 2363
Removing and installing / replacing rear seat (normal) 2363
Removing and installing/replacing rear head restraints (normal) 2364
Replacing seat cover for rear seat (normal) 2365
26 Rear seat, through-loading facility 2366
Removing and installing / replacing actuating mechanism for left rear seat backrest (through-loading system) 2366
Removing and installing/replacing left/right sides of backrest on rear seat backrest (through-loading) 2368
Removing and installing/replacing lock for rear seat backrest (through-loading system), left 2369
Removing and installing/replacing rear head restraints (through-loading system) 2370
Removing and installing/replacing rear seat (through-loading system) 2371
Replacing seat cover for rear seat (through-loading system) 2373
Seats and motorcycle seat 2374
54 Slide/tilt sunroof and soft top 2375
10 Slide/tilt sunroof/panorama glass roof 2375
Repair instructions for bonded seals 2376
12 Slide/tilt sunroof 2379
Adjusting glass slide/tilt sunroof lid 2379
Notes on steel and glass slide/tilt sunroofs (initialization/normalization/learning of characteristic curve) 2381
Removing and installing / replacing wind deflector for glass sliding/tilting sunroof 2383
Removing and installing complete glass slide/tilt sunroof (frame) 2384
Removing and installing glass sliding/tilting sunroof lid 2385
Removing and installing/replacing headliner for glass slide/tilt sunroof lid 2386
Removing and installing/replacing water gutter for glass slide/tilt sunroof (from 09/2001) 2388
Replacing glass slide/tilt sunroof frame 2389
Replacing glass sliding/tilting sunroof lid 2390
Replacing seal for complete glass slid/tilt sunroof frame 2391
Replacing seal for glass sliding/tilting sunroof lid 2392
13 Panorama glass roof 2393
Notes on steel and glass slide/tilt sunroofs (initialization/normalization/learning of characteristic curve) 2393
34 Power Convertible Top 2396
Slide/tilt sunroof and soft top 2397
61 General vehicle electrical system 2398
00 General vehicle electrical system, check 2398
Battery charging calendar 2398
Carrying out a voltage interruption of the 12-V battery 2399
Encode/program control unit(s) 2400
None 2401
Opening plug housings and removing contacts of different plug systems 2406
Repairing airbag cables 2408
Safety instructions for handling vehicle battery 2411
Socket housing (radio connector), Hybrid System MQS/MPQ 2412
Socket housing 42-, 43-, 46-pin, Hybrid System MQS / MPQ 2415
Socket housings, 2x21-, 2x27-pin, Hybrid Systems MQS/MPQ, Elo/Elo Power 2416
Socket housings, 5-pin, 8-pin, System MQS/MPQ 2417
Treating cables and fibre-optic cables 2419
Unlocking and disconnecting different plug connections 2420
11 Wiring harness 2435
Special tools for wiring harness repairs 2435
12 Auxiliary cable 2437
13 Plug connection, terminal 2450
Antenna elbow plug on radio receiver 2450
Butt connector for repairing a plug connection 2452
Circular connector, 13-pin, system D2.5 2455
Circular connector, 20-pin, system D2.5 2456
Circular connector, 7-pin, 8-pin, system D2.5 2457
Circular plugs, 4-, 7-, 10- 12-, 25-pin, System D1.5/D2.5 2458
Connector housing, LCC contact (load current contact) 2459
Control unit plugs, 25-, 35-, 55-, 83-, 88-pin 2461
Crimping annular contacts 2463
Crimping Micro Power Quadlock contacts (MPQ) 2464
Crimping Micro Quadlock System contacts (MQS) 2465
Crimping optical fibres 2467
Crimping stop parts 2469
Cutting off, stripping insulation and cutting optical fibres to length 2472
Cutting to length and stripping insulation from cables 2475
Fuse holder 2476
In-line connectors, 24-/44-pin, Hybrid System MQS/MPQ 2477
In-line connectors, 30-pin, Hybrid System MQS/MPQ 2479
In-line connectors, 30-pin, System D2.5 2481
In-line plugs, 2-pin, System JPT ELA 2482
In-line plugs, 2-pin, System MDK 3 plus 2.8 2483
In-line plugs, 20-pin, System D2.5 2484
In-line plugs, 4-pin, System DFK ELA 2485
In-line plugs, 6- to 50-pin, System Elo 2486
Inline connectors, 15-pin, System D2.5 2488
Inline connectors, 6-, 8-pin, System MQS 2489
Inline plugs, 2-pin, System MPQ 2.8 2490
Inline plugs, 3-, 6-pin, System Elo-Power 2.8 2491
Inline plugs, 4-, 10-pin, System Elo 2492
Inline plugs, 8-, 12-pin, System D2.5 2493
Installing comb connector for retrofitting/repairs 2494
Main relay connector for DME 2498
Relay carrier 2501
Repairing ribbon cables 2503
Socket housing (radio connector), Hybrid System MQS/MPQ 2504
Socket housing 42-, 43-, 46-pin, Hybrid System MQS / MPQ 2507
Socket housings, 2x21-, 2x27-pin, Hybrid Systems MQS/MPQ, Elo/Elo Power 2508
Socket housings, 5-pin, 8-pin, System MQS/MPQ 2509
Socket of tab connector housings 2511
Special tools for wiring harness repairs 2512
Treating cables and fibre-optic cables 2517
20 Battery 2533
Notes on AGM battery 2538
Safety instructions for handling vehicle battery 2546
Threshold values for battery assessment of all batteries (except telephone batteries) 2547
Vehicle battery - closed-circuit current monitoring 2548
21 Battery with holder 2549
Charging battery 2551
Recharge vehicle battery 2552
25 High-voltage accumulator system 2556
Assessing the transport capability of cell block in service workshops 2556
Notes on repair of high-voltage battery unit 2559
31 Switch, sensor 2569
Carrying out steering angle sensor adjustment 2569
Initialise rain sensor 2570
Removing and installing light switch unit 2571
Removing and installing switch unit in center console 2572
Removing and installing/replacing clutch switch module 2573
Removing and installing/replacing fixture for steering column stalk 2574
Removing and installing/replacing operating unit for light switch unit 2576
Removing and installing/replacing rain sensor 2577
Removing and installing/replacing shifters for SMG transmission (both) 2579
Removing and installing/replacing switch for front lumbar support 2580
Removing and installing/replacing switch for SMG transmission (program selector switch) 2581
Removing and installing/replacing switch for windscreen wipers 2583
Removing and installing/replacing turn indicator/headlight dipping switch 2584
Replacing a brake lining sensor 2585
Replacing brake-light switch 2586
Replacing clutch switch for cruise control system 2587
Replacing level switch for windshield washer system 2588
Replacing microswitch for unlocking rear lid 2589
Replacing rocker switch for side-window operation 2590
Replacing switch combination for seat adjustment 2592
Replacing switch for door mirror 2593
Replacing switch for hazard warning system/central locking 2594
Replacing switch on impact cushion for left or right airbag 2596
Replacing switch on sport steering wheel (with connected airbag unit) 2597
Replacing switch unit in center console 2598
35 Control Units, Modules 2599
Encode/program control unit(s) 2599
Initialise rain sensor 2600
Notes on ESD protection (Electro Static Discharge) 2602
Overview, rain sensor (additional work when replacing the windscreen / sensor replacement) 2604
Removing and installing (replacing) the control unit of the electronic immobiliser 2609
Removing and installing/replacing general module 2611
Removing and installing/replacing rain sensor 2612
Removing and installing/replacing ring antenna of electronic immobilizer 2614
36 Relay 2615
Main relay connector for DME 2615
Relay carrier 2616
61 Windscreen wipers 2617
Adjusting left or right windscreen wiper 2617
Checking/adjusting approach angle of windshield wiper arms on front windscreen 2619
Checking/adjusting contact angle of windscreen wiper arms on windscreen 2620
Removing and installing complete wiper console 2622
Removing and installing/replacing both windshield wiper arms 2623
Replacing both windshield wiper blades 2625
67 Headlight cleaning system 2626
Adjusting spray nozzles for headlight cleaning system 2626
Removing and installing/replacing spray nozzles for left or right headlight cleaning system 2627
Removing and installing/replacing washer pump of headlight cleaning system 2629
71 Windscreen washer system 2630
Adjusting windshield washer spray nozzles 2630
Removing and installing/replacing windshield washer pump 2631
Replacing fluid tank for windshield washer system 2632
62 Instruments 2634
21 Instrument carrier 2634
Removing and installing complete instrument carrier 2634
Replacing instrument carrier 2635
63 Lights 2636
10 Headlight adjustment 2636
Adjust the fog lights (with electronic headlight adjustment device MAHA Lite 3) 2636
Adjust the high-beam headlight (with electronic headlight adjustment device MAHA Lite 3) 2637
Adjust the low-beam headlight (with electronic headlight adjustment device MAHA Lite 3) 2639
Adjusting fog lamps 2641
Adjusting headlight for RHD/LHD vehicles 2643
Adjusting headlights 2644
Light patterns from different low-beam headlight types 2645
Notes on headlight adjustment (overview of adjustment options of the lighting functions) 2648
Test requirements for headlights vertical aim adjustment 2650
11 Front lights 2654
12 Headlight 2655
Headlight fogging fault pattern 2655
Notes for replacing the protective cap of the headlight 2656
Removing and installing/replacing left headlight 2657
Removing and installing/replacing left headlight (xenon headlight) 2658
Removing and installing/replacing left headlight vertical aim adjuster (halogen headlight) 2659
Removing and installing/replacing left headlight vertical aim adjuster (xenon headlight) 2663
Removing and installing/replacing lens cover for left headlight (halogen headlight) 2666
Removing and installing/replacing lens cover for left headlight (xenon headlight) 2667
Removing and installing/replacing lens cover for right headlight (halogen headlight) 2668
Removing and installing/replacing lens cover for right headlight (xenon headlight) 2669
Removing and installing/replacing right headlight 2670
Removing and installing/replacing right headlight (xenon headlight) 2671
Removing and installing/replacing right headlight vertical aim adjuster (halogen headlight) 2672
Removing and installing/replacing right headlight vertical aim adjuster (xenon headlight) 2673
Replacing a lower holder for headlight mounting 2675
Replacing bulb for side lights, front left 2676
Replacing bulb for side lights, front right 2677
Replacing control unit for left xenon headlight (saloon/sedan, touring) 2678
Replacing control unit for right xenon headlight 2679
Replacing ignition unit for left xenon headlight (saloon/sedan, touring) 2680
Replacing right ignition unit for right xenon headlight 2681
13 Turn indicators, front 2682
Removing and installing/replacing complete front left or right turn signal lamp 2682
Removing and installing/replacing front left or right additional turn signal lamp (saloon/sedan, touring) 2684
Replacing bulb for turn indicator, front left 2685
Replacing bulb for turn indicator, front right 2686
17 Front Fog Lamps, Additional Lamps 2687
Removing and installing/replacing left or right fog lamp insert (saloon/sedan, touring) 2687
Removing and installing/replacing left or right foglamp insert (M/aerodynamics package) 2689
21 Rear light cluster 2691
Removing and installing/replacing left or right rear light (in side panel) 2691
Removing and installing/replacing left or right tail light (on rear lid) 2692
Replacing a socket housing for left or right rear light (saloon/sedan, touring) 2693
31 Interior lighting 2695
Removing and installing/replacing complete ceiling light 2695
Removing and installing/replacing footwell light 2696
Removing and installing/replacing glovebox light 2697
Removing and installing/replacing left or right interior light (C-pillar or hard top) 2698
Removing and installing/replacing mirror light 2699
99 Working time without specification/lights 2700
Notes for handling bulbs / bulb light sources (exterior lights) 2700
Notes for replacing light bulbs (interior lights) 2701
Notes for replacing the protective cap of the headlight 2702
Replacing bulb for auxiliary turn indicator light, front left or right 2703
Replacing bulb for left or right interior light (C-pillar or hard top) 2704
Replacing bulb for left or right number/license plate light 2706
Replacing bulb for side lights, front left 2707
Replacing bulb for side lights, front right 2708
Replacing bulb for turn indicator, front left 2709
Replacing bulb for turn indicator, front right 2710
Replacing bulb(s) for left or right rear light (saloon/sedan, touring) 2711
Replacing bulb(s) for mirror light 2713
Replacing halogen bulb for high beam headlight on right 2714
Replacing halogen bulb for high-beam headlight on left 2715
Replacing halogen bulb for left or right fog lamp (M aerodynamics package) 2717
Replacing halogen bulb for left or right front fog lamp 2718
Replacing light bulb for footwell light 2720
Replacing light bulb for luggage compartment lighting 2721
Replacing light bulb(s) for ceiling light 2722
Replacing right lamp for xenon light 2723
Replacing the bulb for the left xenon headlight (Saloon, Touring) 2724
Replacing the halogen bulb for the left or right headlight 2725
Safety information for handling bulbs / light sources (exterior lights) 2726
64 Heating and air conditioning 2727
00 Note, overview components climate control 2727
Overview of A/C service station 2729
Overview of refrigerant oil to be filled 2730
11 Heater and controls 2731
Removing and installing / replacing auxiliary water pump 2731
Removing and installing / replacing heater (automatic air conditioner) 2732
Removing and installing heater controls (A/C control) 2737
Removing and installing heater controls (automatic air conditioning) 2738
Removing and installing heating control (heater) 2739
Removing and installing/replacing air duct for right footwell 2741
Removing and installing/replacing heater 2742
Removing and installing/replacing heater (A/C control) 2746
Removing and installing/replacing heater - A/C unit fan 2747
Removing and installing/replacing resistor for heater blower 2750
Removing and installing/replacing servodrive for right fresh-air/recirculated-air flap 2751
Removing and installing/replacing solar sensor 2752
Replacing actuator drive of defrosting flaps 2753
Replacing actuator drive of footwell flap 2754
Replacing actuator drive of ventilation flaps 2755
Replacing evaporator temperature sensor 2756
Replacing front panel (IHKR) 2757
Replacing front plate (air conditioner controls) 2758
Replacing heater controls (A/C control) 2759
Replacing heater controls (automatic air conditioning) 2760
Replacing heater core 2761
Replacing output stage/switch for heater - A/C system blower 2763
Replacing servodrive on gear for flap control (A/C control) 2764
Replacing temperature sensor for heater (in cover for heating element) 2765
Replacing water valve for heater 2766
12 Auxiliary heating with control element 2768
Removing and installing complete electric auxiliary heater (flow heater) 2768
Removing and installing/replacing complete electric auxiliary heater (flow heater) 2769
Replacing complete electric auxiliary heater (flow heater) 2771
22 Air vents and other outlets 2772
Removing and installing / replacing left fresh-air grill 2772
Removing and installing / replacing right fresh-air grill 2773
Removing and installing/replacing center fresh air grill (air conditioning) 2774
Removing and installing/replacing center fresh air grill (heating) 2775
31 Microfilter 2776
Replacing microfilter for interior ventilation 2776
50 Air conditioning, check 2777
A/C performance test 2777
Drawing off, evacuating and filling air conditioning (R134a) 2778
Drawing off, evacuating and filling heating and air conditioning system (R1234yf) 2782
Instructions for handling refrigerant oil (for refrigerant R 134a) 2789
Instructions for opening and part replacement in refrigerant circuit 2790
Leak detection with forming gas 2793
Leak detection with ultraviolet additives (UV additives) (BMW leak-testing case) 2802
Safety informations for handling refrigerant oil 2808
Safety informations for handling tetrafluorethane refrigerant R134a 2809
Troubleshooting by pressure measurement (R 134a) 2810
51 Heating and air-conditioning unit (evaporator), shift elements 2812
Cleaning evaporator 2812
Cleaning evaporator (automatic climate control) 2815
Leak-testing condenser 2818
Leak-testing evaporator 2821
Perform leakage test for evaporator 2823
Removing and installing or replacing expansion valve 2826
Removing and installing/replacing evaporator 2828
52 Compressor 2830
Notes for changing the air conditioning compressor, determining the amount of refrigerant oil (amount of refrigerant oil of new air conditioning compr 2832
Notes on changing the air conditioning compressor, determining the amount of refrigerant oil (amount of refrigerant oil of new air conditioning compre 2838
Removing and installing/replacing complete A/C compressor (M47, M47TU) 2842
53 Condenser and dryer with lines 2846
Leak-testing condenser 2850
Removing and installing/replacing dryer flask for heating and air conditioning system 2853
Heating and air conditioning 2855
65 Audio, navigation, information systems 2857
11 Radio, CD/DVD changer 2857
Removing and installing / replacing CD-changer 2857
Removing and installing/replacing radio control panel (radio navigation) 2858
Removing and installing/replacing radio receiver (built-in unit) 2859
Removing and installing/replacing radio receiver (radio navigation or on-board monitor) 2860
12 Radio, audio amplifier, headunit 2861
Install the correct navigation map (after replacing the head unit as from 07/2015) 2861
Removing and installing / replacing amplifier 2862
Removing and installing/replacing rear speaker 2863
Removing and installing/replacing speaker (front left or right door) 2864
13 Speaker and cover 2865
Removing and installing/replacing speaker (front left or right door) 2865
Removing and installing/replacing speaker (treble speaker in quarterlight mirror) 2866
20 Aerial, interference suppression filter 2868
Antenna elbow plug on radio receiver 2868
Removing and installing/replacing ring antenna of electronic immobilizer 2870
24 Rear window aerial, TV amplifier, wave trap 2871
Removing and installing or replacing antenna amplifier 2871
Removing and installing or replacing block circuit 2872
50 Video and TV sets, central information display (CID) 2873
Removing and installing/replacing video module for on-board monitor 2873
Replacing video module for on-board monitor and loading operating software 2874
52 On-board monitor 2875
Removing and installing complete on-board monitor (widescreen) 2875
Removing and installing on-board monitor 2876
Removing and installing/replacing complete housing with drive for on-board monitor 2877
Removing and installing/replacing housing with drive for on-board monitor (widescreen) 2878
Removing and installing/replacing LC display for on-board monitor 2879
Replacing panel for on-board monitor (control panel, widescreen) 2880
Replacing trim panel for on-board monitor (control panel) 2882
75 Alarm system 2883
Removing and installing/replacing pitch sensor 2883
Removing and installing/replacing ultrasound module 2884
77 Airbag control units, airbag sensors 2885
Notes on scrapping BMW vehicles with gas generators (central airbag control unit, airbag system) 2885
Removing and installing airbag control unit 2887
Removing and installing impact sensor for left or right side airbag (multiple restraint system 4) 2888
Removing and installing/replacing impact sensor for left or right side airbag 2890
Replacing airbag control unit 2892
Replacing impact sensor for left or right side airbag (multiple restraint system 4) 2893
Replacing sensor mat for passenger seat occupancy detector 2894
81 On-board computer 2895
Removing and installing/replacing external temperature sensor 2895
90 Navigation system 2896
Notes on handling navigation computers 2896
Removing and installing/replacing navigation computer with CD-drive 2898
Replacing CD/DVD drive for navigation computer 2900
66 Distance system, Cruise control, remote operation 2903
20 Park Distance Control (PDC) 2903
Removing and installing/replacing a rear ultrasonic transducer (Park Distance Control) 2903
Removing and installing/replacing control unit (Park Distance Control) 2904
67 Electric motor 2906
11 Central locking unit / release drives 2906
Removing and installing/replacing servodrive for tank filler flap 2906
Replacing actuator drive for rear lid locking 2908
13 Mirror adjustment motor 2909
Replacing drive unit for electrically operated left or right door mirror 2909
Replacing drive unit for electrically operated left or right door mirror (with memory) 2910
16 Servo/positioning drives 2911
Removing and installing/replacing left headlight vertical aim adjuster (halogen headlight) 2911
Removing and installing/replacing left headlight vertical aim adjuster (xenon headlight) 2915
Removing and installing/replacing right headlight vertical aim adjuster (halogen headlight) 2918
Removing and installing/replacing right headlight vertical aim adjuster (xenon headlight) 2919
31 Drive, seat adjustment 2920
Removing and installing/replacing drive for backrest angle adjustment (front seat removed) 2920
Removing and installing/replacing drive for longitudinal seat adjustment (front seat removed) 2922
Removing and installing/replacing drive for seat height adjustment (front seat removed) 2923
Removing and installing/replacing drive for seat tilt adjustment (front seat removed) 2924
61 Slide/tilt sunroof / soft top drive 2925
Removing and installing or replacing drive with gear for actuating slide/tilt sunroof 2925
62 Electric motor for power window regulator 2927
Removing and installing / replacing flat motor for front left or right power window unit 2927
65 Drive, roller sun blind/sun visor 2929
Removing and installing or replacing drive for sun roller blind 2929
66 Drive, seat adjustment 2930
Removing and installing / replacing drive unit for lumbar support on left or right front seat (sports seat) 2930
Removing and installing/replacing lumbar support drive mechanism on front seat, left or right 2931
72 Body parts and accessories 2933
00 General 2933
Replacing the seat belt clip 2941
Safety precautions and general information 2942
Safety regulations for handling airbag modules, airbag components and pyrotechnical seat belt tensioners 2943
11 Seat belts 2948
Check list for automatic seat belt 2948
Checking automatic seat belt 2950
Removing and installing or replacing all rear seat belts (compl., with lap belt) 2953
Removing and installing or replacing all rear seat belts (complete, with retractor belt) 2958
Removing and installing/replacing front seat belt 2963
Seat belt tensioner (electrical system notes) 2967
12 Gas generators, airbag modules (with steering wheel airbag 3234) 2968
Airbag system 2968
Deactivation of airbags 2969
Notes on scrapping vehicles with gas generators (airbag system) 2972
Removing and installing / replacing left or right ITS head airbag (model without slide/tilt sunroof) 2977
Removing and installing or replacing airbag module on passenger side 2994
Removing and installing/replacing airbag module on left or right front door 2999
Removing and installing/replacing airbag module on left or right rear door 3001
Removing and installing/replacing left or right ITS head airbag (model fitted with sliding/tilting sunroof) 3002
Safety regulations for handling airbag modules, airbag components and pyrotechnical seat belt tensioners 3005
Scrapping vehicles with passenger airbag and pyrotechnic belt tensioners 3010
Unlocking/locking airbag plug connections 3011
14 Child seat quick connect system 3015
Replacing outer/inner Isofix holders 3015
Body parts and accessories 3016
84 Communication systems 3018
11 Combox, TCB, telephone 3018
Removing and installing / replacing interface for D-Network car phone 3018
Removing and installing / replacing telephone handset with keypad 3019
Removing and installing/replacing eject box (cordless keypad handset) 3020
Removing and installing/replacing eject box (fixed mounting) 3021
Removing and installing/replacing eject box (mobile phone) 3023
Removing and installing/replacing hands-free microphone 3025
Removing and installing/replacing transceiver (fixed mounting) 3027
Replacing cordless keypad handset 3028
21 Handheld, ULF, line compensator 3029
Removing and installing/replacing hands-free charging electronics (cellular phone) 3029
31 Hands-free system (microphone, speaker) 3030
Removing and installing/replacing hands-free system speaker 3030
50 Aerials, Bluetooth aerial 3031
Removing and installing / replacing basic antenna 3031
Replacing multiband telephone antenna 3032
Vehicle preservation 3035
99 Paint 3037
00 General Paint 3037
Paint 3045
Service Information 3053
00 Maintenance 3053
Brake fluid - Operating Fluids Specification 3053
Brake fluid service - extension of the first brake fluid interval to 36 months 3054
Attention! 3055
CBS general - Reset is lost 3056
Engine oil - varying colours/ smell after initial filling in the works 3057
Engine oil service - countries with higher levels of dust: Check the air filter element for contamination 3058
Final drive oil - new oil quality from 07/2011 3059
Handling fault messages / Check Control messages for Run Flat Indicator·RDC (SA2VB) 3060
Note: 3062
Inflation pressure measurement in vehicles with tyre pressure display·RDC·(SA2VB) 3067
Introduction of new service interval for ECE countries (RDE diesel fuel) 3068
New "Maintenance Records" service booklet and maintenance documentation All models 3070
Revised scope of maintenance work 3071
Revised scope of maintenance work, MY 2002 3072
Service intervals for countries with low fuel grade (SA988/SA8KE, SA8KM, SA984, SA8KK, SA8KL, SA8KH, SA8KP) 3074
Service Sheets - Condition-based Service/Pre-delivery Check (ISTA, ISPA, Commercial Service Data) 3078
Standard work scope - expansion of work scope (with slide/tilt sunroof and panorama glass roof) 3080
Emergency Services (BMW/MINI) from issue September 2009 3081
04 12 V vehicle electrical system 3082
Battery recharging intervals for booth vehicles, battery charging calendars and battery tags (12-V battery, high-voltage battery unit) 3082
05 High-voltage electrical system 3084
06 Vehicle-specific notes 3086
Drawbar load sign omitted All with options 235 and 3AC 3086
New repair methods ·Gluing / Riveting· on steel bodies 3087
Warning! 3089
07 Operating fluids 3090
Note: 3090
Brake fluid - Operating Fluids Specification 3092
08 Exhaust-gas test, roadworthiness test 3094
Annual vehicle inspection in compliance with labour protection and accident prevention according to Operating Safety Ordinance BGV D 29 and BBG 916 3094
Changed emissions test indicator BMW Condition Based Service 3096
General and legal information on performing the periodic exhaust-gas (emissions) test in EU countries 3097
Master document for exhaust emission inspection (AU) target data 3101
Master document for vehicle-specific Service Information bulletins All model series up to Model Year 2004 3102
Master document for workshop literature/workshop equipment 3104
Note: 3106
Important: 3110
Note: 3112
Supplement of nominal values for emissions test on new BMW models since 09/2001 3116
Caution! 3118
Test instructions for the exhaust gas test (AU) on BMW vehicles with petrol engines from European emission classification "EURO 6" 3125
Caution! 3132
Note: 3137
11 General maintenance 3139
11 Engine 3140
00 Engine 3140
Note: 3140
Engine 3141
BMW Quality Longlife-04 All 3141
Replace EGR pipe, EGR valve and suspension element for EGR radiator 3143
Replace exhaust-gas recirculation pipe and exhaust-gas recirculation valve 3145
Important: 3147
Engine electrical system 3150
Note: 3150
Introduction of new fuel filler caps for US models E36 Z3 E38 E39 E46 US only 3152
Note: 3158
Note: 3159
Fuel preparation and control 3162
Note: 3162
Note: 3170
Fuel supply 3171
Accidental refuelling with petrol 3171
Note: 3173
Introduction of new fuel filler caps for US models E36 Z3 E38 E39 E46 US only 3180
Important! 3185
Exhaust system 3187
Replacing tailpipe bracket on rear axle crossmember E46 M47TU 3188
Manual gearbox 3189
Note: 3189
Attention: 3192
Note: 3193
Notes: 3195
Notes: 3199
Positive engagement in drive position D delayed E46 E53 E83 E39 with A5S 390R (GM5 transmission) 3200
Notes: 3204
Notes: 3205
Positive engagement in drive position D delayed E46 E53 E83 E39 with A5S 390R (GM5 transmission) 3206
Note: 3210
00 Propeller shaft, general 3211
Important: 3211
Propeller shaft 3214
Important: 3214
Important! 3217
Warning! 3222
Note: 3223
Memo from: _________________ 3224
Memo from: _________________ 3226
Memo from: _________________ 3228
Important! 3230
Warning! 3235
Note: 3237
Changeover of differential oils 3238
Note: 3239
Replacing tailpipe bracket on rear axle crossmember E46 M47TU 3240
Important! 3241
Warning! 3243
Important: 3244
Brakes 3246
Modified wear limit for brake disc / brake pad replacement 3246
Note: 3247
Important. 3252
Important! 3253
Pedals 3258
Important! 3258
10 Wheels 3260
General information on tyre pressure control (RDC) E38 E39 E46 E53 3260
12 Tyres 3262
Inflating tyres with nitrogen (N2) All series 3266
Information on tyre pressure control (RDC) E38 E46 E39 3267
Note: 3268
Important! 3269
41 Body 3274
00 Body 3274
Note: 3274
Body 3278
Cracks in rear axle mount (inspection on customer request) 3278
Note: 3279
Important 3280
New BMW paint brochure 3284
New repair methods ·Gluing / Riveting· on steel bodies 3285
Important! 3287
Replacement of rear axle trailing arm fixture E46 3288
Seal rear left spring strut support bearing E46 /4 3290
Warning! 3292
00 General body equipment 3293
Note: 3293
Front licence plate holder All models 3294
Note: 3295
Note: 3296
Note: 3297
Note: 3298
Note: 3299
45 Trim, instrument trim panel 3300
Note: 3300
Note: 3301
Body equipment 3302
Gear indicator failed 3302
Information sticker exterior paintwork All Models 3303
Radio CD 43: CD is not ejected E46 3304
Stowage compartment E46 3306
Note: 3307
Caution! 3308
Sport seat causes cracking noises E46 3313
Sliding/tilting sunroof - changed function E46 3315
Note: 3316
20 Battery 3320
Note: 3320
Important notes: 3327
General vehicle electrical system 3328
Automatic driving lights in bright conditions switched on 3328
Note: 3329
Brightness variations with seat heating switched on E46 3338
Dipped headlights remain on E46 3339
Exterior mirror reset imprecise E46 3340
Radio station or CD track jumps when volume button is pressed E39, E46, E53 3341
Rain sensor (AIC): Diverse malfunctions E38 E39, E46 3342
Note: 3344
Sliding/tilting sunroof: no automatic functions E38 E39 E46 E53 3345
Sunroof will not open or close E38 E46 3346
Instruments 3348
ASC+T cannot be deactivated, or incorrect indicator light displays in the instrument cluster E46 with automatic stability contro 3348
Double frequency of turn indicator in instrument cluster E46 with trailer tow hitch (option 235) 3350
Fuel gauge reading incorrect E46 3351
Odometer jumps E46 3352
Lights 3353
Headlight delayed switch-off not working correctly E46 3353
Headlight misting E46 3354
Unauthorised replacement of xenon light components 3356
Xenon light intermittently inoperable E46 with xenon light (option 522) 3357
Air outlet at ventilation nozzles not correct E46 with air conditioning (option 530) 3359
Automatic rear-window heater activation inactive E46 3360
Auxiliary heater starts when a door is opened E46 M47 3361
Auxiliary heater: Exhaust odour in vehicle interior E46 M47 3363
Correct fuse assignment for additional water pump 3365
Note: 3366
Failure or continuous operation of electric fan E46 3367
Heater blower fails or runs permanently E39, E46, E53 with air conditioning (option 530) or automatic air conditioning (option 5 3368
Important! 3370
IHKA control panel: LED in A/C button flashes All models with integrated automatic heating and air conditioning (option 534) 3372
Note: 3373
No air throughput in air conditioning mode E46 with automatic air conditioning system (option 534) 3376
Replace heating cut-off relay and correct fuse assignment or auxiliary water pump 3378
Important: 3379
Check side airbag impact sensors and recode the airbag control unit 3380
Attention! 3382
Recode airbag control unit 3386
Important: 3388
90 Navigation system 3391
Software errors in navigation system E38, E39, E46, E53 with navigation system (option 609) E46, E52 with radio navigation syste 3391
Audio, navigation, information systems 3393
Important! 3393
CD changer: Malfunction 3395
Copy-protected audio CD cannot be played E31, E32, E34, E36, E38, E39, E46, E52, E53, E65, E66, E85 3396
Cruise control intermittently inoperable E38 E39 E46 3397
Attention! 3398
Note: 3402
Master document for airbag/belt tensioner 3403
Note: 3404
On-board monitor radio fault patterns E39 E46 E53 with on-board monitor radio (option 602) or with navigation system (option 609 3405
Position inaccuracies in navigation system E38 E39 E46 with navigation system option 606/609 3407
Problems when installing navigation software E38, E39, E46, E52, E53, E65, E66 with radio navigation (option 606) or navigation 3410
Note: 3411
Radio CD 43: CD is not ejected E46 3413
Radio country code E31 E32 E34 E36 E39 E46, E53 with BMW Business CD radio (global receiver) 3415
Radio navigation system: Load operating software 3416
Reception interference in on-board monitor radio E39 E46 E53 Euro with on-board monitor radio (option 602) or navigation system 3418
Retrofit ITS head airbag holder 3419
Retrofitting adapter cable for navigation computer 3421
Software errors in navigation system E38, E39, E46, E53 with navigation system (option 609) E46, E52 with radio navigation syste 3424
System does not switch back to original mode after traffic news announcement E39 with BMW Business radio, E46 with BMW Reverse r 3426
Note: 3427
Time intermittently fails to appear in radio display E46 with BMW Business radio (option 661) 3429
Volume of navigation instructions (option 609) too low E39 E46 E53 3430
Parts and accessories for engine and chassis 3432
00 General 3433
Important: 3433
Attention! 3436
Important: 3442
11 Seat belts 3445
Attention! 3445
Important: 3449
Attention! 3452
Important: 3458
14 Child seat quick connect system 3461
Attention! 3461
60 Various accessories 3465
Attention! 3465
Body parts and accessories 3469
Master document for airbag/belt tensioner 3470
Communication systems 3471
Hands-free set: volume too low E38 E39 E46 with communications package (option 628), car phone GSM (option 629) or complete prep 3471
Information on charging new batteries in cordless handset on GSM car phone E38 E39 E46 E53 with GSM car phone with cordless hand 3475
Nokia mobile phone: Telephone mute intermittently inactive E38 E39 E46 3476
Siemens fixed telephone: Various fault patterns E38, E39 E46 E53 with GSM car phone with cordless handset (option 630) 3478
99 Paint 3481
00 General Paint 3481
Paint 3482
Tightening Torques 3483
03 Tightening specifications 3483
Extract from BMW Group Standard·GS·90003-2 3483
M10 and M10 x 1 - maximum tightening torques acc. to BMW GS 90003-2 3485
M12 and M12x1.5 - maximum tightening torques acc. to BMW GS 90003-2 3486
M4 and M5 - maximum tightening torques acc. to BMW GS 90003-2 3490
M6 and M7 - maximum tightening torques acc. to BMW GS 90003-2 3491
M8 and M8 x 1 - maximum tightening torques acc. to BMW GS 90003-2 3492
Maintenance and general note 3493
0 operating fluid overview 3493
11 Engine 3500
00 Engine 3500
1100 Overview of tightening torques 3500
11 Engine block 3501
Engine block 3501
Cylinder head 3504
Cylinder head with lid 3505
None 3506
13 Oil sump 3508
Oil Pan 3508
14 Case Covers 3509
Case Covers 3509
Connecting Rods and Bearings 3510
Crankshaft and Bearings 3511
Engine block 3512
22 Flywheel 3515
Flywheel 3515
Vibration Damper 3516
Connecting Rods and Bearings 3517
Engine block 3518
28 Drive belt with tensioning and deflecting element 3521
V-ribbed belt with Tension and Deflection Element 3521
30 Control 3522
31 Camshaft 3523
Camshaft 3523
Oil pump with strainer and motor 3526
42 Oil filters and lines 3527
Oil Filter and Lines 3527
Oil Filter and Pipes 3528
51 Coolant pump with drive 3530
Water Pump and Drive 3530
52 Fan 3531
Fan 3531
61 Intake manifold 3532
Intake manifold 3532
62 Exhaust manifold 3533
Exhaust manifold 3533
65 Charger with control 3534
Turbocharger and Control 3534
66 Vacuum pump 3535
Vacuum pump 3535
71 Exhaust-gas recirculation 3536
Exhaust gas recirculation (EGR) 3536
78 CO adjustment, oxygen sensor 3537
Emissions-control, Lambda oxygen sensor 3537
Engine 3538
Case Covers 3538
Preheating Relay 3540
23 Glow plugs 3541
Glow elements 3541
Preheating Relay 3542
Alternator with Drive and Mounting Parts 3543
32 Controller 3544
Governor 3544
Starter and Mounting Parts 3545
42 Starter line 3546
Wires to starter 3546
51 Engine wiring harness 3547
Engine wiring harness 3547
61 Oil pressure, oil temperature, oil level display 3548
Oil pressure switch, oil level sensor (N47, N47S M47T, M47T2, M57T, M57T2) 3548
Oil pressure, oil temperature, oil level display 3549
72 Sensor for control unit 3550
Senders for Control Unit 3550
90 Control unit box 3551
Control Unit Housing 3551
32 Fuel filter 3552
Fuel Filter 3552
Injection Pump, Control Receptacle 3553
52 Injection pump drive 3554
Injection Pump Drive 3554
53 Fuel Injector Nozzles and Lines 3555
Fuel Injector Nozzles and Lines 3555
Senders for Control Unit 3558
16 Fuel supply 3560
Fuel Tank and Mounting Parts 3560
12 Lines 3561
Fuel Delivery 3561
13 Crankcase ventilation, emission monitoring 3562
Tank Ventilation 3562
Fuel pump 3563
17 Cooling 3564
Radiator and Mounting Parts 3565
22 Oil cooler lines 3566
Additional Fan (electric) 3566
Oil Cooler Pipes 3567
40 Fan 3568
Additional Fan (electric) 3568
Cooling 3569
Exhaust Assembly 3571
Exhaust system, complete 3572
Exhaust system 3573
21 Clutch 3574
11 Clutch housing 3574
Bell housing 3574
Clutch Disc and Drive Plate 3575
52 Clutch operation (hydraulic) 3577
Clutch operation (hydraulic) 3577
22 Engine and transmission mounting 3580
11 Engine mounting 3580
Transmission mounting 3580
32 Transmission mounting, automatic transmission 3581
Transmission in general 3583
Case and Cover 3586
Housing with lid 3588
Transmission shafts 3590
Interior Shift Components 3591
41 External Gearshift Components 3592
External Gearshift Components 3592
71 Transmission mounting 3595
Manual gearbox 3596
11 Transmission Case, Oil Sump 3601
Transmission Case, Oil Sump 3601
Transmission housing, transmission oil sump 3602
Transmission Extension, Bearings, Sealing Ring 3605
15 Electrical add-on parts 3606
Electrical fittings 3606
21 Drive/intermediate/output shafts 3607
Input, Intermediate and Output Shafts 3607
22 Planetary drive 3608
Planetary gear drive 3608
23 Release clutches 3609
Shift Clutches 3609
30 Electro-hydraulic control parts and elements 3610
Hydraulic / electric control parts and controlling elements 3610
31 Oil pump 3611
Primary Pump 3611
32 Controller 3612
Controller 3612
34 Shift valves, parking lock 3613
Shift travel valves, parking lock 3613
Shift Valves, Parking Lock 3614
35 Wiring harness, shift elements and sensors 3615
Wire Harness, Shift Elements and Sensor 3615
40 Torque converter 3616
Torque converter 3616
51 External gearshift components 3618
External shift linkage 3618
52 Internal gearshift 3619
Interior Shift Elements 3619
71 Transmission mounting 3620
25 Gearshift 3623
11 Centre shift for mechanical transmission 3623
Shift Console - Manual Transmission 3623
16 Gearshift bracket - Automatic Transmission 3625
Gearshift bracket - Automatic Transmission 3625
Propeller Shaft. complete 3628
Propeller shaft 3633
Transfer box 3634
Twin-clutch gearbox (DKG) 3635
10 Front Axle Suspension 3636
Front Axle Suspension 3636
12 Wishbones and struts including rubber mounts 3638
Axle guide and axle strut 3638
21 Wheel Bearings and Steering Knuckle 3640
Wheel Bearings and Steering Knuckle 3640
31 Spring Struts 3642
Spring Struts 3642
Stabilizer Bar 3643
Steering 3647
None 3648
Steering 3651
Steering 3652
21 Steering column stalk, track rod, steering damper 3654
Steering Arms 3654
None 3656
Steering Column 3657
33 Steering Wheel 3659
Steering Wheel 3659
34 Airbag and airbag steering wheel 3660
Airbag and airbag steering wheel 3660
Pump and Oil Supply 3661
Rear Differential Case with Cover 3665
17 Rear axle differential mountings 3667
Rear axle differential mountings 3667
Output Shaft 3669
31 Rear axle support 3670
Rear axle carrier 3670
32 Trailing arms and struts 3671
Axle guide and axle strut 3671
33 Rear Axle Suspension 3675
Rear axle carrier 3675
Rear Axle Suspension 3676
41 Wheel Bearings 3677
Wheel Bearings 3677
52 Shock Absorbers 3678
Shock Absorbers 3678
Anti-roll bar 3679
34 Brakes 3681
Testing and bleeding brakes 3681
Front Brake 3682
Rear Brake 3683
31 Foot and tandem brake master cylinder 3684
Brake Master Cylinder 3684
32 Brake Lines 3685
Brake Lines 3685
33 Brake servo 3686
Brake Booster 3686
Parking Brake 3687
Pedal Assembly Console 3688
50 Slip control systems (ABS, ASC) 3689
Slip Control System (ABS, ASC+T, DSC) 3689
51 Mechanical hydraulic components 3690
Slip Control System (ABS, ASC+T, DSC) 3690
Brakes 3691
35 Pedals 3693
11 Pedal Assembly Console 3693
40 Accelerator pedal activation 3694
Parking Brake 3694
41 Kick-down 3696
Accelerator Pedal and Linkage 3696
10 Wheels 3697
Wheels 3697
Wheel Rims 3699
14 Electric components 3701
Electric Components 3701
41 Body 3703
00 Body 3703
Reinforcement plate 3703
35 Side Panels 3704
Reinforcement plate 3704
51 Front doors 3705
Door 3705
Body 3706
Front Bumper 3710
12 Rear bumper 3711
Rear Bumper 3711
Trim Parts, Covers, Handle Strip 3712
Mirrors, Finishers, Ashtrays, Consoles 3713
Front Door Locks 3715
22 Door locks, handles, fittings, rear 3717
Rear Door Locks 3717
23 Bonnet catch, locks 3718
Hood/bonnet locks 3718
32 Power windows, manual operation, front 3719
Front Door Windows 3719
33 Power windows, electrical operation, front 3720
Power windows, front 3720
Front door trim panel with armrests 3721
Rear door trim panel with armrests 3722
Side Trim Panel with Armrests 3723
Panel, rear parcel shelf, roller sun blind 3724
47 Floor/luggage compartment/engine compartment, trim panel 3725
Underbody panelling 3725
71 Gaskets and loose body components 3727
Gaskets and loose body components 3727
Body equipment 3729
52 Seats and motorcycle seat 3730
10 Front seats 3730
Front seats 3730
24 Rear seat, normal 3732
Rear Seat (normal), manual 3732
54 Slide/tilt sunroof and soft top 3733
12 Slide/tilt sunroof 3733
Electrical slide/tilt sunroof components 3733
Mechanical components, slide/tilt sunroof 3734
13 Panorama glass roof 3735
Electrical slide/tilt sunroof components 3735
31 Convertible top linkage and operation 3736
Convertible Top, Frame and Actuation (Mechanical Components) 3736
34 Power Convertible Top 3738
Convertible Top, Frame and Actuation (Mechanical Components) 3738
21 Battery with holder 3741
Battery with terminal 3741
31 Switch, sensor 3742
Switch 3742
Windshield Wipers 3744
None 3745
63 Lights 3747
Turn Signals 3747
12 Auxiliary heating with control element 3748
Electric auxiliary heater 3748
52 Compressor 3749
Air conditioning compressor 3749
Refrigerant Lines and Expansion Valve 3750
53 Condenser and dryer with lines 3751
Condenser and Drier with Pipes 3751
Refrigerant Lines and Expansion Valve 3752
Airbag triggering control 3755
67 Electric motor 3756
62 Electric motor for power window regulator 3756
Drives, power windows 3756
71 Parts and accessories for engine and chassis 3757
60 Various accessories 3757
Trailer Hitch 3757
Trailer tow hitch 3758
11 Seat belts 3759
Seat Belts 3759
Airbag modules 3761
Operating fluids, auxiliary materials 3763
Paint 3764
Vehicle Technical Diagnosis 3765
09 Abbreviations 3765
Note: Thanks for your support and feedback. 3765
Engine 3767
Vacuum supply All models 3767
Fuel supply 3770
Note: In this case, EKP = ·Electronic fuel pump control· . 3770
Functional description for fuel supply system 3772
Exhaust system 3795
Exhaust standard EURO 4 and E·OBD for diesel engines 3795
Manual gearbox 3800
Note: 3800
Sequential manual transmission (SMG), based on GS6-37BZ 3831
Note: 3837
Note: 3840
Note: 3862
Note: 3884
Caution! Responsibility resides with the driver at all times 3906
Note: 3914
AGM battery All models from E39 3926
Note: The WDS-DVD does not replace the wiring diagrams on the DIS-CD. 3929
Note: Abbreviations for control unit names 3934
Car and Key Memory 3940
Lights 3945
Note: Option·524 only in conjunction with optional equipment 522. 3945
Note: Option·524 is only available in conjunction with option 522. 3962
Distance system, Cruise control, remote operation 3972
New master key 3972
Communication systems 3981
Caution!·Lock the Bluetooth handset in the eject box when driving. 3981
ULF universal charging and hands-free facility 3987
Fault Elimination 3990
Repair Manuals and Technical Data 3990
FEB-FEB-NED-TESTMODULE-AKTUELL 3990
Engine 3991
AM1101_00597 - Engine, noise 3991
AM1101_00598 - Engine, noise 3992
AM1104_00187 - Operating fluids leak from engine 3993
Manual gearbox 3994
AM2301_00285 - Manual gearbox noise 3994
AM3301_90574 - Rear axle differential noise 3995
AM5205_00469 - Leather, optical complaint 3996
Lights 3997
AM6303_90577 - Headlight fogging 3997
AM6402_00591 - Air conditioning malfunction 3998
SI Special Tools 3999
Repair Manuals and Technical Data 3999
Addition to special tools cabinet All model series 3999
Note: 4000
Workshop equipment sales 4001
Engine electrical system 4002
Release/pressing-off tool 4002
Cleaning set for injector ducts M67 M47 M57 4003
Clutch 4004
Gauge 21 2 070 All Model Series 4004
Body 4005
Pillar protector all 4005
Adapter cable for OBD socket All series 4006
Adapter cable, 3-pin All series 4007
Peripherals box, 26-pin all models 4008
Release/pressing-off tool 4009
Sprayer for air conditioner E39 E46 E53 4010
Lights 4011
Measuring adapter for xenon headlights E38 E39 E46 from 9/98 4011
Sprayer for air conditioner E39 E46 E53 4012
Technical Data 4013
11 Engine 4013
00 Engine 4013
Camshaft, M47TU 4013
Connecting Rods and Bearings, M47TU 4014
Crankshaft and Bearings, M47TU 4015
Cylinder Head with Cover, M47TU 4019
Cylinder Head with Valve Seat Cover, M47TU 4020
Engine in general, BMW, M47TU M47T2 4021
Engine in general, M47 4022
Flywheel, M47TU 4023
Oil Pump with Strainer and Drive, M47TU 4024
Oil Supply E46 / M47TU / D20 4025
Pistons with Rings and Pins, M47TU 4026
Thermostat and Connections, M47TU 4028
Valves with Springs, M47TU 4029
11 Engine block 4030
Engine block 4030
Engine block, M47TU 4031
Cylinder Head with Cover 4037
Cylinder Head with Cover, M47TU 4038
Cylinder Head with Valve Seat Cover, M47 4039
Cylinder Head with Valve Seat Cover, M47TU 4040
Crankshaft and Bearings 4048
Crankshaft and Bearings, M47 4049
Flywheel, M47 4055
22 Flywheel 4057
Flywheel, M47 4057
Connecting Rods and Bearings, M47 4059
Connecting Rods and Bearings, M47 4061
25 Pistons with Rings and Pins 4069
Pistons with Rings and Pins 4072
Pistons with Rings and Pins, M47 4073
31 Camshaft 4078
Camshaft, M47 4078
34 Valves with springs 4084
Valves with Springs, M47 4087
40 Oil supply 4089
Oil Pump with Strainer and Drive, M47 4089
Oil Supply, E46, M47 4091
Oil Pump with Strainer and Drive, M47 4093
Oil Supply, E46, M47 4096
53 Thermostat and engine-proof coolant lines 4098
Thermostat and Connections, M47 4098
12 Ignition lead, spark plugs 4100
Ignition Harness, Spark Plugs, E46 4100
13 Ignition coil 4101
Ignition Coil, E46, M43TU 4101
Ignition Coil, E46, N42 4102
Heating Time Control Unit, M47 4103
Heating Time Control Unit, M47TU 4104
23 Glow plugs 4105
Glow Plugs, M47 4105
Glow Plugs, M47TU 4106
Alternator with Drive and Mounting Parts, E46, (without N42) 4107
32 Controller 4108
Regulator, E46 4108
Starter and Mounting Parts, E46, M47 4109
Starter Motor with Bracket, Solenoid Switch, E46, (without N42) 4110
00 Fuel preparation, check 4111
Checking/adjusting engine and exhaust, E46, M47, AUT, AUT 4111
Checking/adjusting engine and exhaust, E46, M47, MECH, MECH 4112
Checking/adjusting engine and exhaust, E46, M47TU, AUT 4113
Checking/adjusting engine and exhaust, E46, M47TU, MECH 4114
31 Fuel pump with drive and line 4115
Fuel Pump with Drive and Pipe M47 4115
Fuel Pump with Drive and Pipe M47TU, M57TU, M47T2 4116
Distributor Injection Pump, Control Receptacle, Mixture Regulator M47 4117
Distributor Injection Pump, Control Receptacle, Mixture Regulator M57TU, M47TU 4118
Senders for Control Unit, M47 4119
Senders for Control Unit, M47TU 4120
16 Fuel supply 4121
Fuel Tank and Mounting Parts, BMW, E46, Diesel 4121
Fuel Tank and Mounting Parts, E46, Gasoline-driven cars 4122
12 Lines 4123
Fuel Supply, Fuel Level Sender, E46, Gasoline / diesel-driven cars 4123
Fuel Pump, E46, Gasoline-driven cars 4124
Fuel Pump, E46, M47 4125
17 Cooling 4126
00 Cooling, check 4126
Coolant, Cooling System Test, E46, M47 4126
Radiator and Mounting Parts, E39, E46 , M47 4127
Coolant, Cooling System Test, E46, M47 4128
Radiator and Mounting Parts, E39, E46 , M47 4129
21 Clutch 4130
Clutch Disc and Drive Plate 4130
Transmission filling capacities 4131
Transmission filling capacities, BMW, E46, E53, E60, E61, E63, E64, E81, E82, E83, E87, E89, E90, E91, E92, E93, F10, F11, GS6-53DZ, MANUAL 4132
Transmission in general S5D 280Z 4139
Transmission in general S7S 47BG 4140
Transmission in general ZF-S5-16 / MECH 4141
Transmission in general, BMW, 240/5, MANUAL, Overdrive 4142
Transmission in general, BMW, 260/5, MANUAL, Sport 4144
Case and Cover 4149
Case and Cover S6-37BZ/DZ / MECH 4155
Case and Cover ZF-S5-16 / MECH 4156
Housing with lid, BMW, 240/5, MANUAL, Overdrive 4157
Housing with lid, BMW, 260/5, MANUAL, Sport 4159
Transmission Shafts GS6-37BZ/DZ 4164
Transmission Shafts GS6-53DZ / MECH 4165
Transmission Shafts S 5 D 200 G / MECH 4166
Transmission Shafts S 5 D 250 G / MECH 4167
Transmission Shafts S 5 D 310 Z / MECH 4168
Transmission Shafts S 6 S 420 G / MECH 4169
Transmission Shafts S 6 S 560 G / MECH 4170
Transmission Shafts ZF-S5-16 / MECH 4171
Transmission shafts, BMW, 240/5, MANUAL, Overdrive 4172
Transmission shafts, BMW, 260/5, MANUAL, Sport 4174
22 Gearwheels 4179
Gears (Layshaft) GS6-53DZ / MECH 4179
Gears (Layshaft) S 5 D 200 G / MECH 4180
Gears (Layshaft) S 5 D 250 G / MECH 4181
Gears, BMW, 240/5, MANUAL, Overdrive 4182
Gears, BMW, 260/5, MANUAL, Sport 4184
Gears, BMW, ZF-S5-16, MANUAL, Overdrive 4191
23 Synchromesh 4192
Synchronisation guide bushes, BMW, 240/5, MANUAL, Overdrive 4192
Synchronisation guide bushes, BMW, 260/5, MANUAL, Sport 4194
Synchronisation guide bushes, BMW, ZF-S5-16, MANUAL, Overdrive 4201
Synchronisation, BMW, 240/5, MANUAL, Overdrive 4202
Synchronisation, BMW, 260/5, MANUAL, Sport 4204
Synchronisation, BMW, ZF-S5-16, MANUAL, Overdrive 4209
Synchronization GS6-37BZ/DZ / MECH 4210
Synchronization GS6-53DZ 4211
Synchronization Guide Sleeves GS6-37BZ/DZ / MECH 4212
Synchronization Guide Sleeves GS6-53DZ / MECH 4213
Synchronization Guide Sleeves S 5 D 200 G / MECH 4214
Synchronization Guide Sleeves S 5 D 250 G / MECH 4215
Synchronization S 5 D 200 G / MECH 4216
Synchronization S 5 D 250 G / MECH 4217
Synchronization S 5 D 310 Z / MECH 4218
Synchronization S 6 S 420 G / MECH 4219
Synchronization S 6 S 560 G / MECH 4220
Inner shifting parts, BMW, 240/5, MANUAL, Overdrive 4221
Inner shifting parts, BMW, 260/5, MANUAL, Sport 4223
Inner shifting parts, BMW, ZF-S5-16, MANUAL, Overdrive 4228
Transmission in general, BMW, E39, E46, A4S 200R, A5S 325Z 4229
Transmission in general, BMW, E46, E39, E38, E85 4230
Transmission in general, BMW, E39, E46, A4S 200R, A5S 325Z 4231
Transmission in general, BMW, E46, E39, E38, E85 4232
Propeller shaft complete, E46, Three-part propeller shaft 4233
Propeller shaft complete, E46, Two-part propeller shaft 4234
Front axle - ride height E46 / REAR END 4235
General - Track Width / Wheelbase E46 4236
32 Shock absorber 4237
Shock Absorbers E46 4237
50 Front axle differential 4238
Front differential unit E46 4238
Chassis/wheel alignment - normal position E46 / M43TU, M47, M47TU, M52TU, M54, M 4239
Wheel Alignment E46 / REAR END / Low-slung sports suspension 4240
Wheel Alignment E46 / REAR END / Rough road package all up to 09/2001 4241
Wheel Alignment E46 / REAR END / Rough road package, from 09/2001, E46/2/3/C and 4242
Wheel Alignment E46 / REAR END / Rough road package, from 09/2001, E46/4 (except 4243
Wheel Alignment E46 / REAR END / Standard suspension 4244
Power Steering Gear, E46 4245
Pump and Oil Supply E46 4246
Pump and Oil Supply E46 4247
General - track width E46 4248
Rear axle - ride height E46 / REAR END 4249
Rear axle differential E39, E46, E83, E85 / 188K 4250
Rear axle differential E46, E83, E85 / 168K 4251
Rear axle final drive, BMW, E46, 215K 4252
Final Drive Ratio, E46, Sedan 4253
Final Drive E46 4254
Output Shaft, E36, E46 4262
34 Brakes 4263
Testing and bleeding brakes E46 4263
Front Brake 4264
Rear Brake 4265
Parking Brake, E46 4266
10 Wheels 4267
Wheels One-part alloy wheels 4267
Wheels Steel and aluminium strip wheels 4268
Wheels Two-part alloy wheels 4269
Front Bumper 4270
12 Rear bumper 4271
Rear Bumper 4271
63 Lights 4272
Adjustment of lights E30, E32, E34, E36, E38, E39, E46, E52, E60, E61, E63, E64, 4272
Settings for lights, BMW, E30, E32, E34, E36, E38, E39, E46, E52, E60, E61, E63, E64, E65, E66, E67, E81, E82, E83, E85, E86, E87, E88, E90, E91, E92,
4273
12 Headlight 4274
Headlight, BMW, E46, Compact 4274
Headlights, E46, Saloon/sedan, touring, coupé, convertible 4275
Direction indicators E46 4276
17 Front Fog Lamps, Additional Lamps 4277
Front Fog Lamps, Additional Lamps, BMW, E46, Compact 4277
Front Fog Lamps, Additional Lamps, E46, Coupé, convertible 4278
Front Fog Lamps, Additional Lamps, E46, Saloon/sedan, touring from 09/2001 4279
Front Fog Lamps, Additional Lamps, E46, Saloon/sedan, touring up to 09/2001 4280
21 Rear light cluster 4281
Rear light cluster, BMW, E46, SEDAN, SPORTS WAGON, From 09/2001 4281
Rear light cluster, BMW, E46, SEDAN, SPORTS WAGON, up to 09/2001 4282
25 Brake lights 4283
Auxiliary Brake Light, E46 4283
26 Number plate light 4284
Number plate light, BMW, E46 4284
31 Interior lighting 4285
Interior lighting, BMW, E46, Coupé 4285
Interior Lights, E46, Compact 4286
Interior Lights, E46, Convertible 4287
Interior Lights, E46, Sedan 4288
Interior Lights, E46, Touring 4289
50 Air conditioning, check 4290
A/C system, refrigerant amounts 4290
51 Heating and air-conditioning unit (evaporator), shift elements 4291
Heating and air-conditioning unit (evaporator), switching elements 4291
Heating and air-conditioning unit (expansion valve), switching elements 4292
Repair Hint 4293
Form for equipotential bonding screw connections 4293
08 Exhaust-gas test, roadworthiness test 4294
5.1.1 Axles 4294
7.1.1 Installation safety of the seat belts/seat belt buckles 4295
7.1.2 Status of the seat belts/seat belt buckles 4297
7.1.3 Belt force limiter 4299
7.1.4 Seat belt tensioner 4300
7.1.5 Airbag 4301
7.1.6 Supplementary restraint systems (SRS) 4303
7.11 Odometer (if present) 4304
7.12 Driving dynamics control (Electronic Stability Program, ESP) (if installed/required) 4305
11 Engine 4306
00 Engine 4306
Repair notes to renew the cylinder head 4306
Repair notes to renew the engine 4308
Engine 4309
6.1.9 Engine performance 4309
8.2.1.1 Emission control systems 4311
8.2.1.2 Gaseous emissions 4316
8.2.2.1 Emission control devices 4317
8.2.2.2 Exhaust gas opacity vehicles, vehicles registered or in operation prior to 01.01.1980 are excluded 4320
Assessment of the rubber mounts on axle components 4322
2.6 Electronic hydraulic steering (EPS) 4323
34 Brakes 4326
1.2.1 Service brake: Effect 4326
1.3.1 Auxiliary brake (emergency braking): Effect 4331
1.1.6 Duo-servo parking brake 4332
1.1.6 Electronic parking brake 4335
1.1.6 Parking brake, operating lever, reversible ratchet 4341
1.4.1 Parking brake: Effect 4344
50 Slip control systems (ABS, ASC) 4345
1.6 Antilock Brake System (ABS) 4345
52 Electronic components 4346
1.7 Electronic brake system (EBS) 4346
Brakes 4347
1.1.13 Brake pads 4347
1.1.14 Brake drums, brake discs 4348
10 Wheels 4352
5.2.2 Wheels 4352
Cosmetic repairs on wheel rims 4353
12 Tyres 4362
5.2.3 Tyres 4362
00 Integrated suspension system in general 4372
Notes on vehicle tilt (2-axle air suspension) 4372
41 Body 4374
00 Body 4374
6.1.3 Fuel tank and fuel lines (including heater fuel tank and lines) 4374
EMC screws, general information 4389
Filler S1 4390
Transferring hole pattern 4396
Vehicle identification number, general 4398
63 Other flaps 4402
Fuel filler flap emergency release 4402
Assessment of damaged vehicle 4403
Removing and installing/replacing the protective cap on the door handle 4405
31 Front and rear window 4406
Repair of damage caused by stone chips on the windshied 4406
Replace the gel pad for rain-light-solar-condensation sensors 4412
6.2.6 Other seats 4414
00 General vehicle electrical system, check 4415
4.11 Electrical wires 4415
20 Battery 4421
Battery exchange in vehicles with a high-voltage system 4421
Battery replacement information 4422
Instructions for 12 V dual storage system 4423
25 High-voltage accumulator system 4427
Assessing the transport capability of high-voltage battery units in service workshops 4427
Assessment of damaged vehicle 4429
Instructions for handling cell blocks 4432
Notes for lifting high-voltage battery unit 4433
Notes for opening and closing cable straps 4436
Notes for use of adapter cable 24-pin 4439
Notes on earth bonding screw connections 4440
Notes on repair of high-voltage battery unit 4441
Notes on the identification of the high-voltage system 4444
Overview of high-voltage battery unit cooling 4447
Safety information for handling electric and hybrid vehicles 4448
Visual check of the high-voltage battery unit following an accident 4457
27 High-voltage battery unit individual component 4461
35 Control Units, Modules 4462
Replace the gel pad for rain-light-solar-condensation sensors 4462
44 Convenience charging electronics (KLE) 4464
63 Lights 4465
4.1.2 Headlight alignment 4465
11 Front lights 4468
4.1.1 Headlamps status and function 4468
4.1.6 Headlight cleaning system (if required) 4475
Installing headlight repair kit 4476
12 Headlight 4486
4.1.5 Self-levelling suspension devices (if required) 4486
14 Position lamps, rear reflectors 4490
4.2.1 Rear lights status and function 4490
25 Brake lights 4493
4.3.2 Brake lights switch 4493
Lights 4494
4.1.3 Headlamp switch 4494
4.13 Battery (batteries) 4496
00 Note, overview components climate control 4500
Draw off the contaminated R1234yf refrigerant and dispose of it 4500
00 General 4503
8.1.1 Acoustic insulation system 4503
Overview of the clips and unlocking tools for head airbag fastening 4504
99 Paint 4505
99 Disc wheels 4505
Operating Fluids 4514
Foreword 4514
Approval conditions for operating fluids 4515
Vehicle care measures for inventory vehicles (new and used vehicles) as well as vehicles to be taken off the road that are in the hands of customers 4516
Conversion chart 4520
11 Engine 4522
General information 4522
Oil grade/viscosity classes 4524
Engine oil quality 4526
Engine-oil additives 4527
Technically suitable engine oils for BMW Group engines 4528
BMW Longlife-01 4534
BMW Longlife-01 FE 4541
BMW Longlife-04 4543
BMW Longlife-12 FE 4554
BMW Longlife-14 FE+ 4557
BMW Longlife-17 FE+ 4559
SAE 10W-60 4561
Engine oil consumption measurement (only S85 with one oil drain plug) 4564
Engine oil consumption measurement (only S85 with two oil drain plugs) 4569
Record on oil consumption measurement 4573
Overview of consumables 4575
Fuels for spark-ignition engines 4581
Minimum requirements - Fuels for spark-ignition engines 4584
Cleaning agents for fuel injectors 4585
Fuels for diesel engines 4586
Minimum requirements - Fuels for spark-ignition engines 4587
Winter operation with diesel fuel 4588
Cleaning fluid for diesel injection systems 4590
Cleaning agents for fuel injectors 4591
Danger classes 4592
16 Fuel system 4593
Additive for petrol engines 4593
Additive for diesel engines 4594
17 Cooling 4595
Requirements for coolant 4595
Change interval, changing and check of coolant, disposal, cleaning the cooling system 4596
Technically suitable antifreeze and corrosion inhibitor for BMW, BMWi, MINI and Rolls-Royce 4597
BMW antifreeze and corrosion inhibitor G48 4600
BMW antifreeze and corrosion inhibitor HT-12 4602
i3 coolant 4603
BMW antifreeze and corrosion inhibitor G30-91 4604
Coolant additives 4605
21 Clutch 4606
Operating fluids for clutch hydraulic system 4606
Operating fluids for clutch hydraulic system, SMG 4607
Brake cylinder paste, grease in the clutch region 4608
23 Manual Transmission 4609
General information about manual gearbox oil additives 4609
Gearbox oil for BMW manual gearbox from 9/1997 (with yellow label) 4610
Gearbox oil for MINI manual gearbox 4612
Gearbox oil for manual gearbox (with orange label) 4614
Gearbox oil for manual gearbox (with green label) and 4-speed manual gearbox 4618
Gearbox oil for BMW manual gearbox, front-wheel drive 4619
Transmission oil for twin-clutch gearbox GS7D36SG 4620
Operating fluids for clutch hydraulic system (SMG) 4621
General information on automatic transmission fluid (ATF) 4622
Oil additives 4623
Automatic transmission fluid for ZF gearboxes 3HP22, 4HP22, 4HP22EH, 4HP24 4624
Automatic transmission fluid for ZF gearboxes A5S 310Z (5HP-18) 4629
Automatic transmission fluid for ZF transmission GA6HP19Z (6HP19) / GA6HP26Z (6HP26) / GA6HP32Z (6HP32) 4634
Automatic transmission fluid for ZF transmission GA8HP45Z / GA8HP70Z / GA8HP90Z 4635
Automatic transmission fluid for GM transmission A4S 310R (THM-R1), A4S 270R (THM-R1w) 4636
Automatic transmission fluid for GM transmission A4S 200R (GM4), A5S 360R/390R (GM5) 4637
Automatic transmission fluid for GM transmission GA6L45R (GM6) 4642
Automatic transmission fluid for GM transmission GA7AHSCD (AHS-C) E72 Hybrid 4643
Automatic transmission fluid for Jatco transmission A5S 300J (Jatco) 4644
Transmission oil for "BMW" and ·MINI· automatic transmission GACVT16Z (CVT) / GA6F21AW (AISIN) / GA8F22AW (AISIN) 4645
Transmission oil for automatic transmissions GA6F21AW (AISIN) 4646
25 Gearshift 4647
Greasing and assembling gearshift components 4647
Grease for propeller shaft (flexible coupling centre bearing and spline end) 4648
Grease for propeller shaft (constant velocity joint - hub spline) 4649
Technically-suitable transfer box and electric gearbox oils 4650
BMW ATF D2 4651
BMW ATF D3 4656
BMW DTF1 4657
BMW Synthetics OSP 4658
BMW i TF (CLN-4S) 4659
Rear axle differential oil SAF-XO 4660
Hypoid Axle Oil G1 (BOT448) 4661
Manual gearbox oil MTF LT-2 4662
31 Front Axle 4663
Technically-suitable front axle differential oils 4663
General information on high temperature multipurpose greases 4664
Grease for wheel bearing 4665
Mounting aid for rubber bearing installation 4666
Hypoid Axle Oil G1 4669
32 Steering 4671
ZF Gemmer steering 4671
ZF rack and pinion steering 4672
ZF recirculating ball and power-assisted rack and pinion steering 4673
ZF power-assisted recirculating ball steering with H 31 unit 4674
Grease for horn contact 4675
Lubricant for fitting rubber mount 4676
33 Rear Axle 4677
Technically-suitable rear axle differential oils 4677
Output shaft 4679
Wheel bearing 4680
Lubricant for rubber cuff mount 4681
Flange nut, rear axle differential 4682
BMW HOK oil 4683
BMW rear axle differential oil MSP/A 4685
BMW rear axle differential oil SAF-Carbon Mod 4686
BMW rear axle differential oil SAF-XJ Booster 4687
Hypoid Axle Oil G1 (BOT448) 4689
Hypoid Axle Oil G3 (Fuchs Titan EG 4218) 4690
Manual gearbox oil MTF 1 4692
34 Brakes 4693
Handling brake fluids 4694
Approved brake fluids 4695
Brake fluid change intervals 4696
Auxiliary brake materials 4698
35 Pedals 4699
Grease for pedals 4699
36 Wheels and tyres 4700
Tyre fitting paste 4700
Grease for wheel-centring spigots 4701
Hydraulic oils for vehicles with self-levelling suspension 4703
54 Soft top 4704
Hydraulic fluid for convertible top 4704
Lubricating grease for panoramic glass sunroof 4705
64 Heating and Air Conditioning 4706
Refrigerant R134a 4706
Refrigerant oil for R134a 4707
Refrigerant R1234yf 4708
Refrigerant oil Sanden SP-A2 (for C2H2F4/R1234yf) 4709
Coolant i3 for heater circuit (BMW i) 4710
97 Vehicle preservation 4711
General information on preservation measures 4711
Cavity sealant 4712
Underbody protection 4713
Seal 4714
00 00 ... Battery: check display (magic eye); if necessary, recharge
battery
For further information on how to proceed, refer to
Lead calcium batteries, all models.
00 00 ... Battery: checking acid level, topping up with distilled water
if necessary. If necessary, recharge battery.
Important!
Observe safety instructions for handling vehicle battery.
Vehicles with low-maintenance battery:

Check acid level, top up with distilled water if necessary
If level drops below Max. marking, top up distilled water to Max. marking.
Vehicles with maintenance-free battery:
Check charge start by way of magic eye
Important!
For information on how to proceed, refer to
Battery charging.
Issue a separate invoice if the battery is recharged.
00 00 249 BMW engine oil service (M47)
(Change engine oil and oil-filter insert)
Caution!
When working on the oil, coolant or fuel circuit, you must protect the
alternator against contamination.
Cover alternator with suitable materials.

Failure to comply with this procedure may result in an alternator
malfunction.
Note:
Do not damage main flow oil-filter cover, release and tighten with
socket only. When the main flow oil-filter cover is released, the oil
flows from the oil-water heat exchanger back into the sump.
Release main flow oil-filter cover and remove towards top.Installation:

Tightening Torque,
refer to Technical Data 11 42 2AZ.
Installation:
Replace seals and coat with oil.
Remove oil filter element (1) towards top.Installation:

Press oil filter element (1) onto fixture in oil filter housing.
Open cover in engine underguard.
Open oil drain plug or drain off oil.
Installation:
Replace sealing ring.
Tightening Torque,
Top up engine oil.

Complete vehicle and set in horizontal position.
Start engine and run at idle speed until oil indicator lamp goes out.
Switch off engine, wait approx. 5 minutes and then check engine oil level.
Top up engine oil if necessary.
00 00 249 BMW engine oil service (M47TU)
(changing engine oil and oil filter insert)
Caution!

malfunction.
Note:
Do not damage main flow oil filter cover, release and tighten down
with a socket only. When the main flow oil filter cover is released,
the oil flows from the oil-water heat exchanger back into the sump.
Release main flow oil filter cover and take off.Installation:

Tightening torque 11 42 2AZ.
The tightening torque of 25 +5 Nm is stamped in the cover.
Installation:

Open cover in reinforcement plate.
Open oil drain plug or draw off oil through guide tube for oil dipstick.
Installation:
Tightening torque, 11 13 1AZ.
Fill system with engine oil.

Assemble vehicle and set down in horizontal position.
Start engine and run at idle until oil indicator lamp goes out.
If necessary, top up engine oil.
00 00 250 BMW engine oil service incl. supplementary service (M57 / M47TU)

Reset service interval indicator according to factory specification.
Replace microfilter for interior ventilation.
Check brake lining thickness.
Adjust handbrake cables.
Caution!
Otherwise the alternator may malfunction.
Note:
Do not damage main flow oil filter cover; release and tighten down
with socket only. When the main flow oil filter cover is released, the
oil flows from the oil-water heat exchanger back into the sump.
Release main flow oil filter cap and remove towards top.Installation:
Installation:
Withdraw oil-filter element towards top.Installation:

Press oil-filter element onto support in oil-filter housing.
Open cap in engine underguard.
Open oil drain plug or draw off oil.
Installation:
Note:
Illustration from M57.
Top up engine oil.

00 .. . BMW service-inspection (diesel vehicles)
Important!
The operations set out below always refer to the maximum possible scope of a service-
inspection.
The exact scope of the vehicle in question must be printed out with the vehicle identification
number from the KSD CD.
Body / electrical system

Check lighting system: instrument and indication field lighting, heater fan, signal horn, headlight flasher and
hazard warning lights
Windscreen wash/wipe system: check wiper blades and spray nozzle adjustment
Seat belts: check condition of belt strap, function of inertia reel mechanism, locking reel, belt buckle
Locking systems: check status and function, oil and grease if necessary
Battery:
check acid level, top up with distilled water if necessary.
If necessary recharge
Heating/air conditioning: change microfilter / carbon canister
Body and underbody: check for corrosion and damage - except cavities
Convertible only:
Trigger rollover protection system (Convertible) via diagnosis interface. Caution! Remove hard top
or open convertible top first.
Cover for convertible top frame outlet: treat guide with protecting spray
Engine compartment
Fault memory interrogation
Change engine oil and oil filter
Coolant hoses: visually inspect for leaks, check coolant level and concentration, top up if necessary
Caution! Replace coolant at least everyÂ 3 years.
Reset service interval indicator according to factory specifications
Windscreen washer system and intensive cleaning system: check fluid level, top up if necessary
Power steering/ride-height control: visual inspection for leaks, check fluid level, top up fluid if necessary
Fuel cooler: Check for external contamination, clean if necessary
Caution! Change brake fluid in accordance with service interval indicator, no later than every 2 years
Air cleaner: Replace air cleaner element
Chassis / suspension area
Front and rear disc brake pads:
check pad thickness with measuring gauge.
If pads are replaced: Clean brake ducts. Brake discs: Check surface and thickness. If replacing at
rear: check parking brake linings. Grease wheel centering on light alloy wheels.
Check steering for play. Steering tie rods and axle joints, steering gear, sleeves and flexible disc: check
condition
Check clutch drive plate for wear
Transmission (all gears): visual inspection for leaks.
Oil change in manual transmission
Oil change in rear differential
Fuel lines, fuel tank and fuel hoses: visual inspection for routing, condition and leaks
Exhaust system: check condition, routing, mounting and for leaks
Drive shafts: check gaiters for leaks
Brake lines and connections: visual inspection for leaks, damage and correct position
Check handbrake lever travel, adjust according to setting specifications if necessary
Tyres:
Check pressure, correct if necessary (including spare wheel). Check external condition (left/right),
check tread depth and pattern
If level of wear is not uniform, measure and correct wheel alignment after consulting with customer
Replace main fuel filter. (If necessary, shorten filter-change intervals in case of poor diesel quality)
Final check
Check roadworthiness:
check brakes (with rear disc brakes: brake in handbrake)
Steering/power steering
Clutch
Shock absorbers (visual inspection)
Indicator and warning lamps
Check Control
00 00 ... Body and underbody: checking for corrosion and damage -
except cavities
Visually inspect the underbody, wheel arches and frame members for rust and damage.
Important!
If damage to the underbody is identified:
If necessary, remove panels from underbody.
Check mountings and fixtures and brake and fuel lines for damage and correct installation
position.
Rectify identified faults after consulting with customer and issue a separate invoice.
00 00 ... Brake and clutch hydraulic system: checking fluid level, topping up
if necessary
Caution!
Brake fluid is toxic.
Keep brake fluid off painted surfaces of vehicle as brake fluid will
damage the finish.
Check fluid level in expansion tank; if necessary, top up brake fluid to

Max. marking (1) (refer to Service Information Operating Fluids).Caution!
If the fluid level in the expansion tank has dropped to the Min.
marking (2), this means that either the brake pads are worn or the
brake system is leaking. It is not enough merely to top up the brake
fluid. It is absolutely essential to identify what has caused the brake
fluid level to drop.
Note:
It is absolutely essential to rectify any identified faults after consulting the
customer and to issue a separate invoice.
00 00 ... Brake lines and connections: visual inspection for leaks,
damage and correct position
Check brake lines and connections
Visual inspection in visible area for:
leaks; if necessary, check brake fluid level in expansion tank
traces of fluid
damage
crushing/flattening
correct routing of brake lines
correct seating of brake lines in holders
Note:
Detected faults must urgently be repaired after consultation with the customer!
00 00 ... Changing brake fluid
Change brake fluid in accordance with repair instructions
Read and comply with general notes and information on brakes
Note:
Issue a separate invoice for changing the brake fluid.
00 00 ... Changing coolant
Warning!
Danger of scalding!
Only perform this work after engine has cooled down.
For further information on how to proceed, refer to

Draining and topping up coolant
Bleeding cooling system and checking for water leaks
For filling quantity, refer to Technical Data.
Note:
Issue a separate invoice for changing the coolant.
00 00 ... Changing differential oil
Change oil with rear axle differential at normal operating temperature.

Final drive oil, refer to Service Information Operating Fluids.
For filling quantity, refer to Technical Data.
Unscrew drain plug (2), clean and reinstall.

Unscrew the filler screw plug (1).
Pour in differential oil until overflowing. Install filler screw plug (1).
Installation:
Tightening Torque, refer to Technical Data.
00 00 ... Changing engine oil and oil filter
Note:
Change engine oil and oil filter in accordance with repair instructions
00 00 ... Check coolant level, if topping up: checking concentration
Check coolant level in expansion tank. Coolant level must be between Min. and Max. marks. If necessary, top
up coolant to max. fill level. If there is no coolant, also identify the cause and notify the customer.
Check concentration with antifreeze tester (special tools) in coolant expansion tank.
If necessary, drain the differential amount at the coolant drain plug and top up with specified coolant; see
Service Information on operating fluids.
00 00 ... Check fuel cooler for external contamination, clean if
necessary
Remove air duct.
Blow compressed air through air duct from engine compartment in direction of bumper.
Remove coarse dirt from fuel cooler.
Blow compressed air through fuel cooler from rear and thereby remove dirt from radiator fins.
00 00 ... Checking clutch drive plate for wear
Check clutch drive plate for wear during a test drive (see Final check)
00 00 ... Checking handbrake lever travel, adjusting according to
setting specifications if necessary
Checking parking brake
Check handbrake lever travel and adjust in accordance with repair instructions
00 00 ... Checking horn, headlight flashers and hazard warning
system
Horn
Check function.
Note:
In the case of twin-tone fanfares, make sure that both fanfares are working properly.
Headlight flasher
Activate headlight flashers, check high-beam headlights and blue indicator lamp in instrument cluster for correct
operation.
Hazard warning system
Check function.
Note:
After consultation with the customer, rectify faults and issue a separate invoice.
00 00 ... Checking instrument and indication field lighting, heater
blower
Instrument lighting
Check function of instrument and indicator/warning lamps.
Indication field lighting
Check function of light switches; dimmer; controls; heater/air conditioning; rear window demister; radio;
(depending on equipment) on-board computer; power windows; electric sunroof; fog lamp.
Heater
Check function of all blower stages, air distribution and air outlet.
Note
00 00 ... Checking lighting system
Check lighting system for correct operation:
Check headlights, rear lights and associated telltale/indicator lamps
Check headlight adjustment
Check side lights, parking lights, dipped-beam and main-beam headlights for correct operation
Check headlight flasher for correct operation
Check signal horn
Check left/right direction indicators and hazard warning system for correct operation
Check brake lights for correct operation
Check reversing lights and license plate lights for correct operation
Check front and rear fog lights for correct operation
Check interior lights (assembly: interior lights, footwell lights, luggage compartment lights, glovebox
light) for correct operation
Check instrument and indication field lighting
00 00 ... Checking roadworthiness
Checking roadworthiness
Take vehicle for a test drive, checking service and parking brakes in the process
For vehicles with rear disc brakes, brake in parking brake as instructed
Check function of parking brake
Check steering for play, ease of movement and directional stability
Check clutch for problem-free disengagement and non-spasmodic driving off at normal operating
temperature
Check function of all drive positions and driving programs in cars with automatic transmissions
Visually inspect shock absorbers for leaks
Check indicator/warning lamps and Check Control system for correct operation
Check due date for statutory roadworthiness and exhaust emission tests and advise customer of
test dates
00 00 ... Coolant hoses: Perform visual inspection for tightness,
check coolant level and concentration, top up if necessary
Check connections, hose clamps and hoses for coolant residues and damage such as e.g. cracks.
Check coolant level in expansion tank. Coolant level must be between Min. and Max. marks. If necessary,
top up coolant to max. fill level. If there is no coolant, also identify the cause and notify the customer.
Check concentration with antifreeze tester (special tools) in coolant expansion tank.
If necessary, drain off the difference quantity at the coolant drain plug and top up with recommended
coolant (issue a separate invoice).
00 .. ... Description of inspection work
On the following pages the work required for inspections is described.
If necessary, reference is made to the corresponding chapter in the Repair Instructions.
Only carry out the inspection work listed in the inspection sheet which applies to the vehicle.
00 00 ... Diagnostic brief test
Connect BMW diagnosis system (DIS) to diagnosis socket or OBD socket
Switch ignition on
Carry out vehicle identification
Start brief test
Note:
For diagnostics, the brief test is essential for evaluating possible stored diagnostic trouble codes. In
the brief test, the control units are physically identified in succession and their fault memories read out.
Check identified faults and if necessary rectify these faults after consulting with customer.
11 00 300 Engine oil consumption measurement
Attention!
This procedure for measuring oil consumption may not be used for the S 85 due to the oil pan design.
Many complaints about oil consumption are caused by the oil level being measured using the wrong method.
The oil consumption should be measured after a distance of 7,500 km at the earliest, as the process of running
in the engine will not have been essentially completed and the engine oil consumption stabilised until this
distance has been covered.
Engine oil consumption that may occur in an engine can only be determined by the customer on the basis of
the refilled engine oil quantity. As soon as the engine oil level falls below the MAX mark on the dipstick, many
customers top up the engine oil without paying attention to a number of basic rules, such as the vehicle must
be standing on level ground, a certain period of time must be left to allow the oil to flow back to the sump. In
such cases, the available container sizes (e. g. 1-litre can) make it easy to top up above the MAX mark. Too
much added engine oil is damaging to the engine and is consumed more quickly due to the splash effect.
It is therefore recommended to allow the engine oil level to the MIN mark and only then to add the required
engine oil quantity. The distance between the marks is equivalent to approx. 1.0 to 1.5 litres.
The procedure for checking the oil level is given in the Owner's Handbook for the vehicle concerned.
The service delegates will only deal with claims made under warranty if exact measurements by weighing are
available (see below).
Measuring oil consumption by weighing:
To assess a warranty or goodwill claim, only the following oil consumption measurement method by weighing
can be accepted (this must have been carried out by a BMW contractual partner):
Note:
The engine must not leak any oil.
Engine oil may only be drained off when the engine is at its normal operating temperature. The engine
oil temperature must be at least 90 °C and read off on the diagnosis system.
Preparation:
1. Eliminate any leaks and traces of oil before measuring the engine oil consumption.
2. Allow the engine to run at idling speed for 5 minutes, during which the engine oil temperature must not
drop below 90 °C.
3. Unscrew the main flow oil filter cover (the engine oil will flow back into the oil sump from the oil filter
housing).
4. Unscrew the oil drain plug.
5. Allow the engine oil to drain off for 15 minutes.
If necessary, remove the fan/fan cowl.
6. Turn the engine once through 360 degrees by the vibration damper.
8. Retighten the primary flow oil filter.
9. Pour in the specified engine oil quantity for the engine type in question (with filter change).
10. Drive the vehicle for a distance of at least 1,000 km/500 miles. Increasing the mileage will produce
significantly better measuring results.
Measurement procedure:
11. Check the engine for leaks; if the engine is not tight, the examination will not be meaningful.
12. Prepare the measuring container to be able to capture the oil quantity.
drop below 90 °C.
housing).
19. Weight the amount of drained engine oil. (Engine oil has a density of about 0.86 g/cm³ at room
temperature.)
Amount of oil added (cm³) ‐ amount of oil drained off (g): 0.86 g/cm³
Engine oil consumption = —————————————————————————————
mileage reading when draining - mileage reading when adding engine oil
Example:
Volume of oil added at mileage reading 44,800: 4.000 cm³
Weight of oil added at mileage reading 45,900: 2.700 g
4.000 cm3 - 2.700 g : 0.86 g/cm³

Engine oil consumption = —————————————— = 0.78 cm³/km
45,900 km - 44,800 km
0.78 cm³/km = 0.78 l/1,000 km
Test certificate for engine oil consumption:
Vehicle data: _____________________________

BMW (type): _____________________________
Chassis number: _____________________________
Added oil quantity (in ccm): _________________ at kilometre reading:__________

ccm
less drained off oil quantity (in g) : 0.86 _________________ at kilometre reading:__________
(g/ccm) ccm
=> oil consumption: _________________ => mileage: _____________________
ccm km
Oil consumption [l/1000 km] =

_____________ [ccm] oil consumption _____________ [km] mileage
Oil consumption after balancing out: ____________________________ l/1000 km

Oil grade: ____________________________
Oil grade: ____________________________
Viscosity: ____________________________
Cause of damage: ____________________________
___________________________________ ___________________________________
Dealer address Signature
00 00 ... Exhaust system: checking condition, mounting and
inspecting for leaks
Condition
Check exhaust system for corrosion and cracks
Check screw connections on flanged joints and clamping sleeves for damage
Routing
Check that exhaust system is correctly routed and free of obstructions on the underbody
Check that heat shields are fitted and securely seated
Mounting
Check rubber mounts and rubber rings for cracks and whether any are missing
Leaks
Check exhaust system at flanged joints and clamping sleeves for black combustion residues.
Note:
00 00 ... Fault memory interrogation
Connect MoDiC or DIS Tester to diagnosis socket or OBD socket.
Read fault memory.
Note:
For more information, refer to operating instructions for MoDiC or DIS Tester.
00 00 ... Front and rear brake linings: checking lining thickness with
measuring gauge. If linings are replaced: cleaning brake shafts,
checking brake disk thickness and surface, applying grease to wheel
centering on alloy wheels. If rear linings are replaced: checking parking
brake linings
Check brake lining thicknesses with measuring gauge at front and rear
Clean brake shafts
Replace brake linings if they drop below minimum thickness (refer to Technical Data)
Replace brake discs if they drop below minimum thickness (refer to Technical Data) and in event of
scoring, heat cracks, lateral runout or thickness difference
Clean wheel centering on alloy wheels and apply a thin coating of grease
Remove front and (if necessary) rear disc brake pads
Remove and install front disc brake pads
Remove and install rear disc brake pads
Additional tasks when changing rear linings
Remove rear brake discs
Check parking brake lining for porosity and wear
Check ease of movement of expander lock
Note:
Defective brake pads/linings/brake discs must be repaired after consultation with customer and a
separate invoice issued
00 00 ... Fuel cooler: checking for external contamination, cleaning
if necessary
Check fuel cooler for external contamination, clean if necessary
Remove all leaves or any other kind or dirt/contamination from the air intake area of the fuel cooler
00 00 ... Fuel lines, fuel tank and fuel hoses: visual inspection for
routing, condition and leaks
Check fuel lines and hoses and fuel system connections for traces of fluid and for leaks
Check fuel tank(s) and hoses for damage such as cracks, flattening etc.
Check that fuel lines are routed correctly
Check that fuel lines are correctly seated in holders
Note:
Detected faults must urgently be repaired after consultation with the customer!
00 00 ... Heating/air conditioning: replacing microfilter/carbon
canister (shorten replacement interval accordingly in event of larger
buildup of dust)
Changing microfilter, refer to repair instructions:
Microfilter E39
Microfilter E46
Microfilter E53
Microfilter E85
Microfilter E83
Important!
In the E39 the water drain under the brake booster must be checked for contamination and if
necessary cleaned when the microfilter is changed.
Note:
In the case of older model years, issue a separate invoice for replacing the microfilter.
00 00 ... Intake silencer: Renew air filter element (shorten change
interval if heavily clogged with dust)
Renew air cleaner as described in the repair instructions
00 00 ... Locking systems: checking status and function, oiling or
greasing if necessary
Lock car and check that locks and central locking (incl. tank cap) work properly.
Depending on equipment specification, check comfort locking function of windows and sliding sunroof.
Check function and ease of movement at:
Door/luggage compartment/bonnet/hood locks
Door brakes
Door/engine hood/bonnet/fuel filler cap/rear lid hinges
Arrester hooks on engine bonnet/hood
and apply oil or grease if necessary.
00 00 ... Oil change in manual transmission
Carry out oil change in manual transmission in accordance with repair instructions
00 00 ... Oil change in rear differential
Carry out oil change in rear differential in accordance with repair instructions
00 00 ... Oil change in transfer case
Change oil in transfer case in accordance with repair instructions
00 00 ... Output shafts: checking gaiters for leaks
Rotate rear left and right wheels by hand; in so doing, check inner and outer gaiters for damage such as
holes, cracks or porosity
Check gaiters for leaks (emerging grease)
Check that strap retainers are securely attached to gaiters and whether any straps are missing
On all-wheel drive vehicles the same procedure applies to the output shafts on the front axle
00 00 ... Parking brake: checking function, adjusting/repairing as
prescribed
For subsequent procedure, refer to
Checking parking brake adjustment.
00 00 ... Parking brake: checking lining thickness
Remove rear brake disks. For subsequent procedure, refer to
Removing both rear brake disks 34 21 320.
Check brake linings for minimum thickness and traces of wear such as cracks.
Check expansion lever for ease of movement, apply grease if necessary.
00 00 ... Power steering/ride-height control: visual inspection for leaks,
checking fluid level, topping up fluid if necessary
Visual inspection and leak test

Check connections, hoses and steering gear for traces of fluid.
Checking fluid level

Check fluid level with engine switched off at expansion tank of power
steering/ride-height control system.
If necessary, add hydraulic fluid (refer to Service Information Operating
Fluids) up to Max. marking (1).
Important!
If the fluid level has dropped to the Min. marking (2), you must check
the power steering and ride-height control for leaks and issue a
separate invoice for this work.
It is not enough merely to top up the fluid.
00 00 612 Preliminary check prior to general inspection
Preliminary check prior to general inspection:
Check telltale and warning lamps

Warm up brakes on brake test stand
Check front brake
Check rear brake
Checking parking brake
Check low beam setting with tester (determine if low beams are too high)
Visually inspect low beams for installed position and colour variation (compliance with German road
traffic licensing regulations)
Check for correct operation of headlamp range control
Check lighting system (for vehicles without Check Control)
Visually inspect rear brake discs
Check tyres and rims for damage and for correct dimensioning
Visually inspect engine compartment from underneath for coolant and oil leaks
Visually inspect exhaust system for corrosion and check rubber retainer for cracks
Check movement of tie rod ends and check seals for damage
00 00 ... Renew main fuel filter (if necessary, shorten filter-change
intervals in case of poor diesel quality)
Renew main fuel filter as described in the repair instructions
00 00 ... Replacing main fuel filter (shortening change interval if
necessary in event of poor diesel fuel quality)
Replacing fuel filter.
00 00 ... Resetting service interval indicator according to factory
specifications
Special tools required:

61 1 110
For vehicles with diagnosis socket in engine compartment:

Necessary preliminary tasks:
Switch ignition on.
Attach resetter (special tool 61 1 110 ) to diagnosis socket in
engine compartment
Resetting engine oil service

Press yellow button (1) for engine oil service.
Green lamp (2) lights up.
Wait until yellow lamp (3) lights up and then goes out again.
Check that oil service indicator has been reset.
Reset service
Press red button (1) for inspection.
Green lamp (2) lights up.
Wait until red lamp (3) lights up and then goes out again.
Turn off ignition, wait 20 seconds and repeat procedure in order to adapt
interval of annual inspection to inspection.
Check that service interval indicator has been reset.
For vehicles without diagnosis socket in engine compartment:

For vehicles which do not have a diagnosis socket in the engine
compartment, the service interval indicator is reset via the instrument
cluster or the Diagnosis and Information System (DIS).
For details of the exact procedure, please refer to the Owner's
Handbook for the vehicle in question or the Diagnosis and Information
System (DIS).
00 00 ... Seat belts: checking condition of belt strap, function of
inertia reel mechanism, locking reel, belt buckle
Belt strap, retractor mechanism, belt interlock
Pull out strap and make sure it emerges without jerking.
Belt strapj:
folding
unravelling
pinches
cracks and tears
traces of melting
Check retaining button on tongue of strap
for damage and proper installation.
Retract belt strap; here the inertia reel mechanism must retract the strap automatically and without squeaking
noises, the last section of the strap may have to be fed in.
Pull out belt strap in short tugs - locking reel must lock.
Belt buckle
The tongue on the belt strap must easily snap into place with an audible click.
When the ”Press” button is pressed, the tongue must be ejected from the buckle under spring pressure.
Note:
If the seat belt is damaged, you must replace the seat belt completely after consulting the customer;
issue a separate invoice for this work.
Instructions on how to proceed, refer to Checking automatic seat belt .
00 00 ... Steering components: checking for zero clearance, leaks, damage
and wear
Checking play:
Steering wheel:
Move steering wheel back and forth and check for play
Tie rod joint:
There must no clearance between tie rod arm (2) and tie rod
joint (1).
Checking for leaks:

The following illustration shows the arrangement of the power steering components and lines.
1 Pump 6 Hollow screw

2 Power steering cooler 7 Container
3 Return line 8 Suction hose
4 Steering gear D Sealing ring
5 Pressure line
Check all visible connections, hoses, lines and steering gear for traces of
fluid.
Checking for damage and wear:
Check gaiters, flexible disc and axle and tie rod sleeves for damage (e.g.
cracks, holes), for leaks or missing clamping bands on gaiters.
00 00 ... Steering fluid reservoir: checking fluid level, topping up if
necessary
The steering fluid must be topped up if the level in the steering fluid reservoir is below the Max. marking.
Bleeding power steering.
00 00 ... Transmission (all gears): visual inspection for leaks.
Inspect visible area of all transmissions for traces of fluid, remove underbody protection if necessary
Rectify identified faults after consulting with customer and issue a separate invoice
00 00 ... Tyres: checking inflation pressure, correcting if necessary
(incl. spare wheel), checking external condition, tread depth, pattern. In
event of nonuniform wear, carry out measurement and correction of
wheel alignment
Checking tyre inflation pressure:
Check tyre inflation pressure in accordance with information plate on B-pillar
The inflation pressure in the spare wheel must be 0.5Â bar higher than the maximum specified value
on the information plate
If necessary, initialize Run Flat Indicator
Checking tyre condition:

Check tread depth of all tyres with tyre tread gauge
Check tyre tread surfaces and side walls for incisions and foreign particles such as nails or screws
Check tyre tread pattern for localized flattening and wear on one side; if necessary, carry out
wheel/chassis alignment after consulting with customer and issue a separate invoice for this work
Note:
For details of approved wheel-tyre combinations, refer to KSD CD
For reasons of driving safety, only use tyres of the same type and tread pattern on a single
vehicle
Inform customer of any incorrect or worn tyres
00 00 ... Underbody incl. all visible components: checking for
damage, leaks, corrosion
Visual inspection in visible area for:
damage
Crushing (brake lines, electric cables, fuel lines)
For correct routing of electrical leads (brake pad sensor, pulse generator)
Check mountings and fixtures and brake and fuel lines for damage and correct installation position.
For leaks (transmission, fuel system, brake components, steering)
Traces of fluid (remnants of oil, coolant, fuel)
Corrosion (exhaust system, body ...)
Note:
Advise customer of identified defects; if necessary, rectify defects after consulting customer.
00 00 ... Vehicle care measures for inventory vehicles (new and
used vehicles) as well as vehicles to be taken off the road that are in
the hands of customers
Action Vehicles Execution
Remove the protective transportation film New vehicles Do not remove the
protective film if the
vehicle is kept
outdoors;
Note the
instructions on how
to remove
protective film
Release parking brake New vehicles In general

Used In general
vehicles
Customer In general
vehicles to
be taken off
the road
(note to
customers)
Engage gear or selector lever position "P" for automatic transmission New vehicles In general
Used In general
vehicles
Customer In general
vehicles to
be taken off
the road
(note to
customers)
Check the covers of the interior equipment New vehicles In general
Increase the tyre pressure to 3.5 bar New vehicles In general

Used In general
vehicles
Customer In general
vehicles to
be taken off
the road
(note to
customers)
Charge battery New vehicles See battery

charging calendar
Used See battery
vehicles charging calendar
Customer Every 6 weeks;
vehicles to
be taken off Every 12 weeks for
the road vehicle batteries
(note to that have been
customers) disconnected from
the vehicle
electrical system;
Notify customers of
vehicle-specific
procedures for
electric or hybrid
vehicles
Change the brake fluid and reset CBS Used Change before
vehicles vehicle handover to
customer if service
is due shortly (see
CBS display ->
Brake fluid service)
Check convertible top for potential damage New vehicles Generally before
handover to the
customer
Used Generally before
vehicles handover to the
customer
If possible, keep convertibles in roofed areas New vehicles In general

Used In general
vehicles
Customer In general
vehicles to
be taken off
the road
(note to
customers)
Check for damage to paint, the exterior or interior New vehicles Generally before
handover to the
customer
Used Generally before
vehicles handover to the
customer
Change engine oil and oil filter at engine operating temperature New vehicles No change
Used Prior to handover to
vehicles (not customers as from
applicable to a 12 month
vehicles with immobilisation
Premium period
Selection
certificate)
Customer Prior to handover to
vehicles to customers as from
be taken off a 12 month
the road immobilisation
(note to period
customers)
Check coolant composition Used In general
vehicles
Customer In general
vehicles to
be taken off
the road
(note to
customers)
Dry the parking brake and footbrake by applying the brake New vehicles In general
Used In general
vehicles
Customer In general
vehicles to
be taken off
the road
(note to
customers)
Apply surface protection: vehicle surface wash including interior Used In general
vehicle cleaning and subsequent paint and chrome-part care. Clean vehicles
the rubber seals of the flaps and doors and apply talc or rubber care
product. Use materials approved by BMW for cleaning and vehicle Customer In general
preservation to recondition engines, engine compartments, vehicle vehicles to
underbodies, axles and assemblies. be taken off
the road
(note to
customers)
Switch on the air conditioning for approximately 10Â min each month New vehicles Required to ensure
circulation of the
refrigerant oil
Used Required to ensure
vehicles circulation of the
refrigerant oil
Customer Required to ensure
vehicles to circulation of the
be taken off refrigerant oil
the road
(note to
customers)
00 00 ... When driving on a race track
Caution!
The customer must be informed that, in particular, the brake pads, wear indicator and the flat tyre
monitor installed as standard are not designed for race track operation. The vehicle is also not
designed for motor sport competition racing.
Excessive loading of the vehicle, e.g. by operating it on a race track or in motor sport competition
racing, is not covered by the warranty.
If the customer still wants to drive on a race track, the following aspects must be considered/checked,
at least:
The vehicle, or rather the engine, should be carefully run in before operating it on the race track. A run
in period of at least 2000 km.
Recommendation: Carry out an oil change after the run in period.
For driving on a race track, the following extensions must be considered and implemented on the vehicle.
Model: ......................................................................................
Vehicle identification number: .................................................................
Scope of checks before driving on the race track:

Vehicle check OK Comment
Perform a comprehensive vehicle check service.
-> Scope of the vehicle check service
Engine OK Comment
Perform oil-level check..
-> If necessary, top up to the maximum level.
Transfer box (affects only F39 X2 M35i / F40 M135i xDrive / F54 JCW ALL4 / F60 JCW OK Comment
ALL4)
Perform transfer box oil change.
Cooling OK Comment
Visual inspection of the radiator for contamination.
-> Draw off contamination.
Brake system OK Comment
Check the age of the brake fluid - see Service Booklet/Service history.
-> The age of the brake fluid should not exceed 1 year.
Check filling level in brake fluid expansion tank.
Check the brake pad thickness on the front axle.
-> Wear material thickness ≥ 9 mm
-> Ideally, install new brake pads.
Recommendation for M-vehicles: Use Sport brake pads, if available for that model.
Check the brake pad thickness on the rear axle.
-> Wear material thickness ≥ rear axle ≥ 8 mm
-> Ideally, install new brake pads.
Recommendation for M-vehicles: Use Sport brake pads, if available for that model.
Check the brake disc thickness on the front axle.

-> Minimum brake disc thickness: ≥ Minimum brake disc thickness + 1 mm
-> Ideally, install new brake discs.
Check the brake disc thickness on the rear axle.
-> Minimum brake disc thickness: ≥ Minimum brake disc thickness + 1 mm
-> Ideally, install new brake discs.
Visual inspection of the brake line and brake hose for tightness, damage and porosity.
Wheels / tyres OK Comment
Check wheels/tyres for suitability for operation on the race track
-> Winter tyres, all-season tyres and tyres on steel rims are absolutely unsuitable.
Recommendation: Use Sport tyres.
Check the tyre pressure of all the tyres and adjust, if required.
-> In order to increase the service life and tyre performance, a reduction in the tyre pressure
is recommended for the race track. To do this, proceed as follows:
1. Drive the tyres warm.
2. Set the tyre pressure according to the prescribed value on the tyre pressure label for
partial loads.
3. Initialise RDC.
Note: The display of tyre inflation pressure is possible only up to an operating
temperature of systems of 120 °C. At higher temperatures, which can be reached
during racing operation, the display is suppressed and a CC message is issued. After
cooling down, the system functions again without limitations.
Background: The tyre pressure increases due to the increase in temperature in the tyre when operated on
the race track. This reduces the contact surface of the tyre to the road, leading to an increased temperature
load on the running surface. The adjustment of the tyre pressure in tyres that have been driven warm as
opposed to tyres in a cold state leads to a reduction in the pressure and thus, due to an increased tyre
contact area, to a more equal load on the tyre.
Extensions when driving on a race track:

Warm up OK Comment
Drive a warming up lap.
> Bring the engine up to operating temperature. Fast driving at a medium rpm level and
medium dynamics.
Cool down OK Comment
Drive a cooling down lap.
-> Fast driving at a medium rpm level and medium dynamics. Avoid brake load as far as
possible.
Scope of checks after driving on the race track:

Engine OK Comment
Carry out an oil-level check according to the Owner's Handbook.
-> If necessary, top up to the maximum oil level.
Front axle transmission (only affects G15 with N63 engine) OK Comment
Perform oil change on front axle transmission.
Transfer box (affects only F39 X2 M35i / F40 M135i xDrive / F54 JCW ALL4 / F60 JCW OK Comment
ALL4)
Perform transfer box oil change.

Rear axle differential (only affects G29 Z4 M40i / G20 M340i / G20 M340i xDrive ) OK Comment
If an adjusted rear axle differential is installed.
-> Perform oil change.
Cooling OK Comment
Visual inspection of the radiator for contamination.
-> Draw off contamination.
Brake system OK Comment
Check filling level in brake fluid expansion tank.
Check the brake pad thickness on the front axle.
-> Replace brake pads when the remaining brake pad thickness is undershot (min. thickness
3.7 mm)
Check the dust boots on the brake calipers of the front axle for damage.
Check the brake pad thickness on the rear axle.
-> Replace brake pads when the remaining brake pad thickness is undershot (min. thickness
3.7 mm)
Check the dust boots on the brake calipers of the rear axle for damage.
Check the brake disc thickness and their state on the front axle.
-> Replace brake discs when:
Drop below the minimum brake disc thickness
Scoring
Heat cracks
Thickness difference
Check the brake disc thickness and their state on the rear axle.
-> Replace brake discs when:
Drop below the minimum brake disc thickness
Scoring
Heat cracks
Thickness difference
Wheels / tyres OK Comment

Note to customer: Perform the following points for wheels/tyres immediately after the racing
track operation and before driving on public streets.
Check wheels/tyres for damage.
Check wheels/tyres for minimum tread depth.
Check the tyre pressure of all the tyres and adjust, if required.
1. Allow tyres to cool down.
2. Set the tyre pressure according to the prescribed value on the tyre pressure label.
3. Initialise RDC.
Background: Adjustment of the tyre pressure in cold tyres, as otherwise it can lead to tyre pressure control
warning messages due to the low pressure.
Vehicle check OK Comment
Perform a comprehensive vehicle check service.
-> Scope of the vehicle check service
........................................... ........................................... ...........................................

Date Mechanic Workshop Supervisor
00 00 ... Windscreen wash/wipe system: checking washer fluid
reservoir and spray nozzle adjustment
Check wiper blades for cracks; if necessary, replace wiper blades after consulting with customer
Check wipe pattern for smearing; if necessary, replace wiper blades after consulting with customer
The spray jet must emerge uniformly from the spray nozzle, replace nozzle if necessary and issue a
separate invoice.
Check spray nozzle adjustment of windscreen washer system, adjust if necessary
(On the E85 and E83 the spray nozzles are preset at the factory and cannot be adjusted later)
Check spray nozzle adjustment of headlight washer system, adjust if necessary, refer to
(On the E85 and E83 the spray nozzles are preset at the factory and cannot be adjusted later)
Important!
Do not under any circumstances use a needle or similar to adjust the spray nozzles as such an
implement would damage the water channels in the nozzle!
00 00 ... Windscreen washer system and intensive cleaning system:
checking fluid level, topping up if necessary
Top up windscreen washer fluid reservoir, if necessary rear window washer fluid reservoir and (depending
on equipment specification) intensive cleaning reservoir up to edge or mark.
Important!
A ph-neutral BMW window cleaning agent (antifreeze in winter) must always be added to the water.
00 00 ... Work instruction for removing the protective film
Note:
The protective film is applied to new vehicles at the works. The dealer
must guarantee only expert removal of the protective film.
The protective film should be removed 48 hours before vehicle
handover to the customer.
The protective film can be easily removed from the affected surfaces.
Polishing is necessary only in exceptional cases.
Further information on the protective film is available in the document
"Frequently asked questions on surface protection".
Instructions for removing the protective film:

In order to reduce the amount of force required, the film can be torn
at the edge and pulled off in narrower strips.
Remove the film in a surface temperature range of -10 °C to +50 °C.
Excessively high temperatures can lead to adhesive residue being
left on the surface.
In order to achieve the recommended temperature for pulling off the
adhesive film from the vehicle after direct exposure to the sun, it is
possible to carry out a car wash with applied protective film in order
to cool the vehicle down.
Car wash and surface inspection:

Check vehicle surface after the car wash.
Any adhesive residue left on the vehicle surface can be removed
by rubbing by hand or using a cleaning agent R2 (part
number 83 19 0 417 324) or stain remover (part
number 83 11 9 407 816) and a lint-free cloth.
Procedure in the event of paint swelling:

Any paint swelling normally disappears within 48 hours.
Higher temperatures (infrared lamp) accelerate this process.
Polishing of the surfaces is necessary only in rare cases if the heat
treatment does not result in success.
00 Danger of poisoning if oil is ingested/absorbed through the skin
Danger of poisoning!
Ingesting oil or absorbing through the skin may cause poisoning!
Possible symptoms are:
Headaches
Dizziness
Stomach aches
Vomiting
Diarrhoea
Cramps/fits
Unconsciousness
Protective measures/rules of conduct:

Pour oil only into appropriately marked containers
Do not pour oil into drinking vessels (drinks bottles, glasses, cups
or mugs)
Observe country-specific safety regulations
First aid measures:

Do not induce vomiting.
If the person affected is still conscious, he/she must rinse out their
mouth with water, drink plenty of water and consult a doctor
immediately.
If the person affected is unconscious, do not administer anything by
mouth, place the person in the recovery position and seek
immediate medical attention.
64 00 ... Information on using cleaning agent/paints (personal protection
equipment)
Warning!
Use of cleaning agents/paints not compliant with instructions can
cause serious injuries or burns!
Handling cleaning agents/paints can trigger allergic skin and
respiratory reactions!
Important!
Observe following instructions:
Store cleaning agents/paints only in a secure cabinet.
Keep cleaning agents/paints away from naked flames and
other sources of ignition.
Protect cleaning agents/paints from high temperatures and
direct sunlight.
Always keep an eye douche on hand, change the water
regularly (once a month).
Important!
Observe following instructions before use:
Manufacturer's instructions (on container/packaging)
Hazard warnings (on container/packaging)
Manufacturer's instructions on package insert
Material safety data sheet of manufacturer
Product information in EPC
National market regulations
Important!
Observe following instructions during use:
Do not eat, drink or smoke while working with these products.
Avoid direct contact with skin and eyes.
Wear personal protective clothing/equipment.
Ensure that all enclosed areas are well ventilated or extract
fumes directly.
Immediately change working clothes soiled with cleaning
agent/paint.
After finishing work, wash your hands and apply protective skin
cream.
Important!
Follow hazard warnings and wear personal protection equipment!
First Aid:
If product comes in contact with eyes, immediately flush with running
water for about 10 - 15 minutes. Seek the advice of eye specialist.
In the event of skin contact and where applicable an allergic skin
reaction, clean the affected areas immediately with soap and water
and then apply silicone-free skin cream. Seek advice of physician.
If an adhesive product is swallowed, rinse mouth/parts of mouth
thoroughly with running water. Drink 1-2 glasses of water. Do not
induce vomiting. Consult a doctor.
After inhaling vapours ensure ample supply of fresh air. Keep calm,
keep respiratory tracks clear and call doctor.
Recycling:
Dispose of cleaning agents/paints in a professional manner!
Observe national/country-specific disposal regulations.
64 53 ... Instructions for desiccant insert replacement
32 1 270
A desiccant insert that is in a correctly functioning, sealed heating and air conditioning system does not have
to be changed at regular service-inspection intervals.
However, the dryer flask or desiccant insert must absolutely be replaced in the event of:
contamination of the refrigerant with swarf (e.g. when the compressor is clamped).
With depressurised and/or completely drained refrigerant circuit.
With a refrigerant circuit, which was closed using special tool 32 1 270 but remains open for more than 24
hours.
The desiccant insert cannot be replaced in the following vehicles:
1-Series E8x, 3-Series E9x from 12/2008
E84, E89
1-Series F2x, 3-Series F3x
BMW i 01 without heat pump
In these vehicles, the condenser for the heating and air conditioning system must be replaced.
BMW i 01 with heat pump
On this vehicle the low pressure battery must be replaced.
61 00 ... Notes on handling the high pressure cleaner
Warning!
Only used a high pressure cleaner approved by BMW!
Only specially trained persons of 16 years of age or older may work
with the high pressure cleaner.
Check the high pressure cleaner and electrical wiring for visible
damage.
Only use at a suitable location.
Attention!
Pay attention to following hazard warnings:
Danger of injury due to water jet
Contact with hazardous substances in spray
Risk of skidding on wet floor
Risk of stumbling due to hoses and cables
Comply with notes and instructions on handling cleaning
agents !
Risk of scalding when cleaning with hot water.
On electric or hybrid cars, the safety instructions for handling
with hybrid cars are to be complied with.
Warning!
The following personal protective equipment is to be used:
Safety goggles/face guard

Suitable gloves
Apron
Rubber boots
Ear protectors
Safety shoes
Attention!
Notes on washing a vehicle with a high pressure cleaner:
Do not wash directly on gaskets and control units during
engine
washes.
A minimum distance of 30 cm must be adhered to for tyres and
tyre valves.
A minimum distance of 30 cm must be adhered to for the soft
top and painted parts.
Do not use if engine is still hot.
Do not exceed maximum water temperature of 60Â degrees.
Do not spray directly onto cameras/sensors.
Attention!
For your own safety, we recommend that you do not wash on
the high-voltage components in electric or hybrid vehicles.
00 Risk of injury if oil comes into contact with eyes and skin
Danger of injury!
Contact with eyes or skin may result in injury!
Impaired sight
Irritation of the eyes
Reddening of the skin
Rough and cracked skin

Wear protective goggles
Wear oil-resistant protective gloves
First aid measures:

Eye contact: Rinse eyes immediately with plenty of water for at
least 15 minutes; if available, use an eye-rinsing bottle. If irritation of
the eyes persists, consult a doctor.
Skin contact: Wash off with soap and water immediately. If irritation
persists, consult a doctor.
Note: Do not use solvents/thinners.
00 Safety instructions for handling oil
Warning!
Danger of poisoning if oil is ingested/absorbed through the skin!
Risk of injury if oil comes into contact with eyes and skin!
Recycling:
Observe country-specific waste-disposal regulations.
Measures if oil is unintentionally released:

Personal precautionary measures: Danger of slipping! Keep non-
involved persons away from the work area. Wear personal
protective clothing/equipment.
Environmental protection measures: Prevent oil from draining into
drain channels, sewerage systems, pits, cellars, water and the
ground.
Limiting spread: Use oil blocks to prevent the surface spread of oil.
Cleaning procedure: Bind and dispose of escaped oil with
nonflammable absorbents.
Note: Do not flush oil away with water or aqueous cleaning agents.
00 01 ... Symbols used and information in repair instructions
Warning!
Precautionary rules and measures which protect mechanics and
other personnel against injury (including life-threatening injuries).
For example: Warning!

Risk of scalding!
Important!
Specific instructions and precautionary measures which prevent
damage to the vehicle or to vehicle parts. Failure to comply with the
above will invalidate any warranty claims.
The caution symbol is used in all repair instructions.
However, use of the warning word ”Caution!” is not binding in every
case.
The notes, instructions and precautionary measures mentioned
above retain their validity.
Warning!
High-voltage system - danger to life!
Before beginning work, follow the applicable safety rules and
perform the necessary preliminary work.
Note:
High-voltage symbol for hybrid cars (electrically powered vehicles) E72
and MINI E.
Warning!
Before beginning work, follow the applicable safety rules and
perform the necessary preliminary work.
Note:
High-voltage symbol for hybrid car (electrically powered vehicle) from
F04.
Note:
Particular information on improved procedures for operation, testing,
adjustment and upkeep.
Also indicates the end of a repair section.
Recycling:
Observe country-specific waste disposal regulations
General information:
Refers to other instructions: such as e.g.:
Necessary preliminary tasks;
Further instructions: refer to operating instructions for balancing machine.
Replacement:
Carry out programming/encoding.
Note:
Many electronic control units must be programmed/coded (e.g. when
replaced).
Note (symbol for diagnosis system):

Connect BMW diagnosis system
Important!
Read and comply with notes on protection against damage from
electrostatic discharge (ESD protection).
Note:
Electronic control units and other electronic components - if handled
incorrectly - can be damaged or destroyed by electrostatic discharge.
Special tools required: Note:

List of special tools needed in these repair instructions.
Important!
Do not oil or grease component or tool.
Note:
Oil and grease will impair or damage the function of the component or
tool.
Warning!
Laser beam!
For example:
Adjusting device emits laser beam. Do not look into the beam!
Note on laser class.
Important!
Use eye protection for the following operations.
For example:
Fuel can emerge spontaneously at high speed when the fuel delivery
line is released!
Important!
Use ear protection for the following operations.
Important!
Use eye protection and ear protection for the following operations.
Important!
Use face protection for the following operations.
Important!
Use protective gloves for the following operations.
Avoid skin contact.
Important!
Use eye protection and protective gloves for the following
operations.
Avoid eye contact and skin contact.
Warning!
Danger of explosion!
First aid measures:

Note on first aid measures that need to be administered
immediately.
00 02 001 Raising the vehicle using a vehicle lift
Warning!
Danger to life!
Read and follow operating instructions for vehicle hoist.
Do not exceed approved load-carrying capacity and load distribution
of vehicle hoist.
Weight compensation may be necessary due to the loading
situation of the vehicle.
This also applies in the event of considerable removal of parts or
conversions on the vehicle.
Note:
The vehicle hoist must comply with the relevant statutory/country-
specific accident prevention regulations and be serviced according
to the regulations.
Caution!
Risk of damage!
Before driving onto a vehicle hoist, make sure there is sufficient
ground clearance between the vehicle hoist and the vehicle.
The vehicle may only be raised with the vehicle hoist at the four
jacking points.
Caution!
All four jacking points (1) must be available!
Never raise the vehicle without the jacking points (1)!
Caution!
Risk of damage!
Align support plates (2) of lifting platform arms to jacking points (1) in
such a way that no adjoining components are touched and thereby
damaged.
Caution!
Risk of damage!
Align the rubber block (2) with the jacking points (1) in such a way
that no adjoining components are touched and thereby damaged.
Never raise the vehicle without rubber blocks (or rigid foam
blocks)!
There is a major risk of damage to the vehicle underbody!
00 02 000 Raising vehicle with trolley jack
Warning!
Vehicles without jacking point (is secured to the front axle support
at the centre) must not lifted or moved using the trolley jack!
Use only BMW-distributed/approved trolley jacks which have rubber

plate fixture points.
Trolley jacks must be regularly serviced and always checked for
functional reliability before they are used!
To avoid the vehicle from gliding off the trolley jack, the rubber
grommet must be checked for damage before each use!
Raise vehicle at the front:

Pay attention to the different versions of the jacking points.
Lift vehicle in the area of the marked surface (1).
The front spoiler/spoiler edge must be removed if required.

E67t: Attach jacking point (part ordering via Electronic Parts Catalogue).
Slide front trolley jack centrally below the vehicle, till the mounting plate
with spacer buffer is located below the jacking point.
Raise vehicle using a trolley jack.
Raise vehicle at the rear: Caution!

Risk of damage!
It is not permitted to raise the vehicle at the rear axle differential!
00 00 ... Microencapsulated screws
Screw securing adhesive is a means of preventing a screwed connection

from being loosened by external influences.
Once the screw has been coated with adhesive, the adhesive remains
inactive until such time that it is activated by the encapsulation breaking
when the screw is inserted and then cures (hardens) at room
temperature.
Installation note:
Screw connection must be completed within 20 mins. (start of
curing)
Microencapsulated screws must not be retightened
Thread of nut must be cleaned beforehand in event of repeated use
61 12 ... Information on intelligent battery sensor (IBS)
Notice! Do not connect the charger to the 12 V charging socket
The 12 V charging socket is supplied with voltage by the rear power distribution box via relay. This
relay drops out after terminal 15 OFF. This means that a trickle charger connected at the 12 V charging
socket will be disconnected from the battery. Only charge the battery via the jump start terminal point.
Only then can the voltage supply be registered by the vehicle.
Warning! Danger of destruction in event of mechanical strain

Do not introduce any additional connections at the battery negative terminal.
Do not modify the grounding cable. The ground cable also serves heat dissipation.
Do not establish any connection between the IBS and the sensor screw.
Do not use force when disconnecting the pole shoe from the battery terminal:
Do not pull on the ground cable.
Do not place any tools under the IBS to lever off the pole shoe.
Do not use IBS connections as levers.
Use a torque wrench and set tightening torque in accordance with repair instructions.
Do not release or tighten down sensor screw (Torx screw).
Avoid contact between IBS and ground.
Warning! Danger of destruction to IBS and wiring upon battery replacement

The IBS and wiring can be destroyed by mechanical strain upon battery replacement. Therefore
avoid mechanical strain.
The size (capacity) of the battery required for the car is coded in the Car Access System (CAS).
Use the battery size (capacity) installed as standard upon battery replacement.
Recode the Car Access System (CAS) when installing a battery with a different capacity.
Register battery replacement via Service functions in diagnosis system.
Delete fault code entries in the Digital Engine Electronics (DME) associated with battery
replacement.
Always proceed in accordance with the repair instructions.
Note: Battery draining possible in spite of the intelligent battery sensor IBS being fault-free.
A battery can be drained (e.g. with lights or radio switched on) even when the IBS functions
perfectly in conjunction with power management.
For this reason, only exchange the IBS when there is a corresponding fault code entry!
12 00 ... Notes for disconnecting and connecting battery
Observe safety informations for handling vehicle battery.
Before disconnecting battery:
Turn off the ignition and other electrical loads/consumers to prevent sparking when reconnecting.
Note:
If the ignition is not turned off when the battery is disconnected, fault memories may be set in some
control units.
Attention!
There is a danger of mixing up battery cables: If the positive battery cables and negative battery
cables are the same colour and you are in doubt, follow the polarity to the battery, then mark and
cover the wires.
On vehicles with radio code: After disconnecting the battery, the radio code must be re-entered.
Therefore obtain the radio code card from the customer beforehand. Note stored stations and
restore them after connecting the battery.
Stored settings of the on-board computer and clock will also be lost.
All available ignition keys with infrared transmitter must be recoded for vehicles with first
generation infrared central locking.
General notes on disconnecting battery:

Do not disconnect battery leads and leads from alternator and starter motor while engine is running.
On vehicles with IBS at negative battery terminal:
Do not under any circumstances pull/lever off pole shoes by force.
Do not under any circumstances release the hexagon socket screw of the IBS.
Detach the terminal of the battery earth lead from the vehicle battery and the auxiliary battery if available.
Cover battery negative terminal(s) and secure.
When work is carried out on the electrical system, faults may be caused in the fault memories of some
control units when the battery is connected.
When installing battery terminal: Tightening torque 61 21 1AZ.
After connecting battery:
Attention!
The scope of application of some systems may be restricted after an open circuit.
Likewise, individual settings may be lost.
Settings or activations must be carried out, depending on the equipment specification.
For example:
Vehicles with automatic engine start‐stop function (MSA):
MSA function is active only after teach-in time (vehicle must not be woken for a period of approx.
6 hours) > if necessary, notify customer of the situation
E46 (all-wheel drive vehicle) / E53 / E83: Carry out steering angle sensor adjustment
Activate slide/tilt sunroof, if necessary
If necessary, activate power windows
If necessary, activate mirror with compass
Only E60, E61, E63, E64, E70, E71, E90, E91, E92, E93: mount steering angle
Vehicles with a two‐battery system

Starter and system battery
A circuit for the starter battery and a circuit for the system battery are part of a two-battery system. An auxiliary
control unit monitors both circuits. Depending on the situation, the circuits are connected to or isolated from
the auxiliary control unit via a cut-off relay.
Two AGM batteries, whose design and properties are described in AGM batteries, are used as a storage
battery.
Attention!
These batteries must not under any circumstances be charged with a voltage in excess of 14.8 V.
Rapid programs must not be used either.
Receiving/giving starting aid via jump start terminal point

The engine can be jump-started with an external voltage supply via the jump start terminal on the right side of
the engine compartment.
Note:
The starter battery is isolated from the alternators when the bonnet is open.
Giving starting aid via the jump start terminal point is thus limited by the capacity of the starter battery when
bonnet is open.
Charging starter and system batteries via jump start terminal point
The starter battery is charged as a matter of priority with a charger connected to the jump start terminal. The
voltage at the starter battery is the decisive factor in determining whether the system battery is also included
in the charging operation. The auxiliary control unit automatically detects a charging operation at a charging
voltage at the starter battery of ≥ 13.5 V. The cut-off relay is closed and thus the system battery is connected
in parallel. Both batteries are now charged.
Prerequisite:
Terminal 61 inactive
If terminal 15 becomes "active" during the charging procedure, the cut-off relay is opened immediately and
again only the starter battery is charged.
Note:
When the bonnet is open, the cut-off relay is also opened in normal operation when the engine is
running.
A special mode can be set by means of diagnosis for workshop/garage operation. The cut-off relay is
closed from terminal R in this operating mode. This mode is automatically reset once a distance of
5 km has been driven.
Trickle charging
The increased standby current consumption can be compensated for via the jump start terminal point with the
aid of the "Acctiva easy" trickle charger (Service Information 2 03 05 205).
Attention!
The cigarette lighter is isolated from the electrical system after terminal R ”OFF” on a timed basis
(60 mins.), thereby interrupting charging of the system battery via the cigarette lighter. This is
prevented if the battery switch (on the right side of the luggage compartment behind the trim panel) is
turned on and off again twice within 2 seconds.
61 20 ... Notes on AGM battery
Introduction
In September 2002, the first so-called VRLA batteries, better known as AGM batteries came into use. (VRLA
stands for Valve Regulated Lead Acid, i.e. lead-acid battery with pressure relief valve; AGM stands for
Absorbent Glass Mat, i.e. absorbent glass-fibre fleece).
The constantly increasing energy demand of modern vehicle electrical systems calls for ever more powerful
battery solutions. A modern luxury-class vehicle has some 100 actuator motors that have to be fed with
electrical current. Added to these are safety, environmental and comfort elements which are increasingly
becoming standard features, such as e.g. Antilock Brake System (ABS), Dynamic Stability Control (DSC),
steering assistance (EPS), electronic chassis and suspension control, air conditioning and navigation system.
Current consumption is considerable even when the vehicle is not in use.
The somewhat higher price compared with a battery of similar size is fully balanced by the following benefits:
greatly longer service life
improved starting reliability at low temperatures
reliable starting of engines with high starting current requirements, e.g. high-performance diesel engines
100 % freedom from maintenance
low risk in the event of an accident (reduced environmental risk)
Service life of AGM batteries
Item Explanation Item Explanation
1 Available capacity [%] 2 Mileage [thousand km]
3 AGM battery 4 Lead-calcium battery
5 50 % capacity limit
In contrast to conventional lead-calcium batteries, the sulphuric acid in a battery with fleece technology is not
held freely in the battery housing. Rather, 100% of the sulphuric acid is bound into the mats of the glass-fibre
fleece (separators). For this reason, no battery acid can escape if the battery housing is damaged. In addition,
the AGM battery is sealed to be airtight. This is possible because the gases are converted back into water by
the permeability of the separators.
Brief component description
The AGM battery has a black housing and the so-called "Magic Eye" is missing.

1 Positive grille with silver alloy 2 Positive plate
3 Negative grille 4 Negative plate
5 Separator made of glass-fibre fleece 6 Set of positive plates

7 Set of negative plates 8 Block of plates
9 Block box with base strips
Construction
The AGM battery differs from the conventional lead calcium battery as follows:
larger plates: Larger plates allow a 25% larger power density.
Separators made of glass-fibre fleece: These can cause an up to 3-times higher cycle stability to be
reached. This improves the cold starting capability, the power consumption and service life.
Airtight housing with pressure relief valve (please refer to ”How it works”):
The inspection plugs are sealed and can not be opened.
Battery acid bound in glass-fibre fleece: Battery acid is not found free in the housing as before, but is
rather bound 100% in the glass-fibre fleece. This gives increased security against the acid escaping and
thus reduces the environmental risk.
How it works
The AGM battery differs from conventional batteries in its non-polluting and substance-retaining behaviour
during charging.
When a battery is charged, the electrolysis process emits the gases oxygen and hydrogen.
In a conventional wet lead calcium battery, the two gases hydrogen and oxygen are dissipated into the
atmosphere.
In an AGM battery, the two gases are converted back into water: The oxygen which is created at the
positive electrode during charging passes through the permeable glass fibre fleece to the negative
electrode. At the negative electrode the oxygen reacts with the arriving hydrogen ions in the electrolyte
to form water (oxygen cycle).
In this manner, the gas and thus also the electrolyte are not lost.
Only in the event of an excessively heavy build-up of gas, i.e. excessively high pressure build-up (20 to
200 mbar), does the pressure relief valve discharge the gas. In this process, the pressure relief valve does
not allow any oxygen in the air to enter. Because the pressure in the battery is regulated by a valve, the AGM
battery is also known as the VRLA battery (valve-regulated lead acid).
Notes for Service department
It is necessary when handling an AGM battery to observe some particular points pertaining to battery changing
and installation location.
Charging
Warning! Do not charge the AGM battery with > 14.8 V. Do not use rapid-charging programs!
When charging removed batteries (so-called stand‐alone batteries), do not exceed the maximum
charging voltage of 14.8 V at room temperature. Also, for charging via the external start connection
point, the maximum charging voltage of 14.8 V at room temperature must not be exceeded. The
battery can be damaged even if the AGM battery is only briefly charged with a charging voltage higher
than 14.8 V. A charging voltage of more than 14.8 V is usually used in quick-charging routines.
Installation location
Warning! Do not install the AGM battery in the engine compartment.
The AGM battery must not be installed in the engine compartment on account of the high spatial
temperature differences, otherwise its service life will be significantly shortened.
Housing
Warning! Do not open AGM batteries.
On no account may AGM batteries be opened, as the ingress of oxygen from the atmosphere would
cause the battery to lose its chemical balance, rendering it unserviceable.
00 00 ... Information/warning labels
1 Engine compartment 3 Rear end

2 Interior 4 Underfloor
Location: Information/warning label: Country:
Various components Replacement identification ‐spare parts‐ US, CDN

Various components Anti-theft protection US, CDN
Engine compartment (1):

Battery Battery sticker Gulf States
Electronics box cover High-voltage identification Worldwide
Headlights/engine compartment Mercury (xenon headlights) Worldwide
Engine compartment/raw air snorkel Aluminium screws/bolts Worldwide
Cylinder head cover Ignition coil Worldwide
Engine compartment/end panel BMW High Performance Oil US, not CDN
Engine compartment/end panel Premair US
Engine compartment ICES CDN CDN
Engine compartment/hood/bonnet Refrigerant Worldwide
Engine compartment/hood/bonnet Production date Australia, Great Britain
Engine compartment/hood/bonnet Exhaust gas Australia, US, CDN
Engine compartment/brake booster Brake fluid CDN
Engine compartment/hood/bonnet Exterior paint Worldwide
Engine compartment/hood/bonnet BMW genuine spare parts Worldwide
Interior (2):
Windscreen, top right Airbag ‐windscreen Europe
Windscreen CCC China
Windscreen Vehicle identification number US, CDN, Gulf States, Great Britain &
South Africa
I Drive A/C menu US, CDN
Passenger Airbag, instrument panel US, CDN
compartment/instrument panel
Interior/sun visor Airbag ‐sun visor US, CDN
Steering wheel/speedometer Top speed ‐210 km/h‐ Only with optional Germany
equipment and for car rental
Complete vehicle, bodyshell:

B-pillar Airbag symbol (front passenger) Worldwide (not US and CDN)
B-pillar Vehicle identification number Brazil
B-pillar Manufacturer's certificate US, CDN, Gulf States
B-pillar Tyre inflation pressure Europe, US, CDN, Australia
B-pillar Runflat indicator Worldwide
B-pillar Side airbag Worldwide
B-pillar Nameplate China
B-pillar EC type plate with model designation, vehicle identification Worldwide, not US, CDN, Japan, Australia,
number, colour code Gulf States
Door, driver's Towing Worldwide
side
Rear end (3):

Fuel cap/hood/bonnet Independent heating Europe
Filling area Refuelling US, CDN, Europe
Filling area, instrument cluster (plug) OBD system US, CDN
Trim, striker Nose weight (only with optional equipment) Worldwide
Trim, cross-member (through-loading) Lock, through-loading (only with optional equipment) Worldwide
Luggage compartment cover Retractable hardtop Worldwide
Luggage compartment trim panel on side panel Retractable hardtop Worldwide
Tool box lid (E60) HWS fluid US
Rear lid trim (E61) HWS fluid US
Underfloor (4):
Vehicle jack Vehicle jack Australia
Front axle support Airbag (basic setting) Worldwide
Tension strut with hydro-mount Do not lash down Worldwide
Key:
US = United States
CDN = Canada
CCC = Car Communication Computer
OBD = On-Board Diagnosis
64 53 ... Instructions for replacement of air conditioning capacitors
and radiator/coolers
Attention!
Even when they are correctly installed or due to normal driving, radiators (oil cooler, radiator, charge air
cooler) or air conditioning condensers may show slight impressions or deformations on their discs (1).
A slight sag with a large radius for the air conditioning condenser is also permissible.
As long as tightness/function are not degraded and an adequate distance of a few mm between the
radiator and air conditioning condenser remains in place, this is not damage in either case.
Radiators or air conditioning condensers are not to be replaced in these cases!
Note:
The deformations shown in Fig.Â (1) can be bent back with a standard fin comb..
Damage to lines carrying media or on the flat pipe require exchange of the radiator or air conditioning
condenser (2-6).
Dryer flask ( integrated in the air conditioning condenser):

Round dents/depressions are permitted.
The air conditioning condenser is not to be replaced in this case.
65 90 ... Notes on handling navigation computers
Important!
Risk of damage!
The navigation computer must not be cut off from the voltage
supply for as long as the LED on the computer remains on. (the LED
goes out after approx. 1 minute).
Software installation:
The navigation software must be loaded with terminal 15 activated and
the navigation system ready for operation.
Make sure in so doing that the voltage supply is stable. If necessary,
connect a battery charger to the vehicle.
The charging procedure must not be interrupted (terminal 15 remains
activated).
The software is loaded when the operating software CD is ejected.
Note:
To ensure full operation of all the communications components, it is
necessary in new cars to insert a Road Map CD (DVD) in the navigation
computer.
This is absolutely essential as certain functions are disabled for
distribution channels.
These functions will only be available again after a Road Map CD (DVD)
has been inserted. The mode preset at the factory is automatically reset
when this CD (DVD) is inserted.
When replacing navigation computer:

Carry out vehicle programming/encoding.
Only E46 and E83 with radio navigation system (SA606):
Connect diagnosis system to vehicle.
Switch on ignition (must not be switched off throughout the
procedure)
Start session
Selection via path:
Vehicle
Change language - Set navigation to corresponding language
Create action plan
Accept action plan
Upon request from the diagnosis system, insert the current
BMW navigation system CD into the navigation system drive.
Wait for the BMW navigation system CD to be ejected from the
navigation system drive (the navigation software is not fully loaded
until this happens)
Follow the instructions on the radio navigation system display
Carry out vehicle programming/encoding
To update the navigation software:

procedure)
Insert the current BMW navigation system CD into the navigation
system drive
until this happens)
64 50 ... Instructions for handling R 134a refrigerant
Warning!
Although R 134a at normal temperature is non-toxic, non-flammable and not explosive in air in any
mixture ratio, it is still essential to follow various safety precautions.
The filled refrigerant circuit of the A/C system is subject to excess pressure. When carrying out repairs on the
air conditioning, it is absolutely essential to draw off the refrigerant.
Do not weld or solder on to filled A/C systems or in rooms into which R 134a may have leaked. Exposure to
flames or high temperatures (≥ 50 °C) may give rise to toxic decomposition products (fluorine gas). For this
reason, do not smoke either.
R 134a must be drawn off, cleaned and returned to the air conditioning with a service station following the
relevant operating instructions.
Avoid all contact with liquid or gaseous R 134a. Wear safety goggles and gloves when working on the
refrigerant circuit. R 134a acting on the skin can cause frostbite. Rinse affected body parts thoroughly with cold
water. If R 134a gets into your eyes, likewise rinse with plenty of water and, if necessary, remove contact
lenses if worn. Then seek immediate medical attention. Likewise seek immediate medical attention if you
experience problems after inhaling R 134a fumes.
As a gas, R 134a is colourless, odourless and heavier than air. If it enters the atmosphere, this may result in
an imperceptible danger of asphyxiation or in cardiac palpitations, especially in workshop pits. Ventilate rooms
adequately; if necessary, turn on installed extractor systems.
For a properly functioning air conditioning, it is essential to have the greatest possible levels of cleanliness
when working on the air conditioning and the best possible evacuation (at least 30 minutes dehumidification
from refrigerant circuit) before each filling of the air conditioning.
R 134a absorbs moisture very easily. Therefore, seal off opened pipes, condenser, evaporator, compressor
and dryer flask immediately with plugs.
With exchange parts, the plugs may only be removed immediately before the lines are connected.
In the event of warranty claims, the used parts must be provided with seal plugs to be able to determine the
cause of the damage.
If an air conditioning has been completely drained by leakage, accident or repair, the drier element must be
replace as excessive moisture may have entered the system.
Store filled refrigerant pressure cylinders in such a way that they are not exposed to direct sunlight or other
heat sources (max. 45 °C). Also avoid exposing them to mechanical stress (e.g. by dropping).
In the event of fire, carbon dioxide (CO2), extinguishing powder and a sprayed water jet are deemed to be
suitable extinguishant. Cool reservoirs at risk with a sprayed water jet (risk of bursting!).
Important!
After each refilling of an air conditioning, check that protective caps of filling valves are hand-tight. They
serve as additional seals.
64 50 ... Instructions for handling R1234yf refrigerant
Work on the refrigerant circuit may only be carried out by experts!
Avoid all contact with liquid or gaseous R1234yf. Wear protective goggles and gloves when working on the
refrigerant circuit.
Follow safety information for handling refrigerant R1234yf!
Warning!
Although R1234yf at normal temperature is non-toxic, non-flammable and not explosive in air in any
mixture ratio, it is still essential to follow various safety precautions. At higher temperatures, R1234yf
is inflammable.
As a gas, R1234yf is colourless, odourless and heavier than air. If it enters the atmosphere, this may result in
Store filled refrigerant pressure flasks so that they are not subject to direct sunlight or other heat sources (at
maximum 45 °C). Also avoid exposing them to mechanical stress (e.g. by dropping).
Do not weld or solder on to filled air conditioning systems or in rooms into which R1234yf may have leaked.
Exposure to flames or high temperatures (≥ 50 °C) may give rise to toxic products of decomposition
(hydrofluoric acid). For this reason, do not smoke either.
suitable extinguishing agents. Cool reservoirs at risk with a sprayed water jet (risk of bursting!).
If the protective caps on the filler valves are difficult to open, there is a risk of injury from leaking valve inserts
(high pressure).
The filled refrigerant circuit of the A/C system is subject to excess pressure. Before carrying out repairs on the
A/C system, it is absolutely essential to draw off the refrigerant.
Before conducting repairs, check the actual pressure drop on the pressure gauge of the A/C service
station
R1234yf must be drawn off, cleaned and returned to the A/C system using an A/C service station following the
For a properly functioning A/C system, it is essential to have the greatest possible levels of cleanliness when
working on the A/C system and the longest possible evacuation (at least 30 minutes dehumidification from
refrigerant circuit) before each filling of the A/C system.
R1234yf easily absorbs moisture. Therefore, seal off opened pipes, air conditioning condenser, evaporator, air
conditioning compressor and dryer flask immediately with seal plugs.
If air conditioning has been completely drained by a leak, accident or repair, the desiccant insert must be
replaced as excessive moisture may have entered the system.
With replacement parts, the plugs may only be removed immediately before the lines are connected. In the
event of warranty claims, the old parts must be provided with plugs to be able to determine the cause of the
damage.
Installation note:
After each refilling of an air conditioning, check that protective caps of filling valves are hand-tight. They serve
as additional seals.
64 50 ... Notes on the refrigerant (R134a, R1234yf) and refrigerant oil
Attention!
Specific to the country , 2 different refrigerants (R134a, R1234yf)
are used.
Specific to the country, the vehicle and the year of manufacture 2
different refrigerant oils (ND-8, Sanden SP-A2) are used.
Before carrying out repairs on the refrigerant circuit, always
determine which refrigerant/refrigerant oil is used in the vehicle!
Refrigerant: This information can be found on the type plate on the
bonnet.
Refrigerant oil: This information can be found on the type plate on
the front flap in vehicles with a production date from 2013.
R1234yf refrigerant is used in the following countries:

Observe notes on handling R1234yf refrigerant!
Europe Asia America

Belgium Great Britain Malta Sweden Israel USA
Bosnia and Ireland Macedonia Switzerland Turkey Canada
Herzegovina
Bulgaria Iceland The Slovakia India*
Netherlands
Denmark Italy Norway Slovenia South
Korea
Germany Croatia Austria Spain
Estonia Latvia Poland Czech
Republic
Finland Liechtenstein Portugal Hungary
France Lithuania Romania Cyprus
Greece Luxembourg Serbia
*Only applies to vehicle models with Europe version. All other vehicle
models have R134a.
Introduction of R1234yf refrigerant:

European countries listed in the table, Turkey and Israel:
BMW i as of 09/2013
from 07/2016, BMW, MINI, RR
USA and Canada:
from 07/2016 BMW, BMW i, MINI
South Korea:
The introduction date may vary slightly according to the specific country
and model.
The refrigerant R134a will continue to be used in all other countries.

Observe notes on handling R134a refrigerant!
Refrigerant oil Sanden SP-A2 is used for both, R1234yf and R134a.
Observe notes on handling refrigerant oil!
Attention!
I01, I12 with production date up to 08/2014:
In the national-market version with R134a a wrong
refrigerant oil is present on the type plate
Always use Sanden SP-A2
(Part number of Sanden SP-A2: 2 339 920)
Attention!
Only vehicles with a production date from 09/2013 and R1234yf
refrigerant/Sanden SP-A2 refrigerant oil can be filled using the A/C
service station for R1234yf.
In addition to vehicles with a production date from 09/2013, also all
previous vehicles without the electric A/C compressor with R134a
refrigerant and both ND-8 and Sanden SP-A2 refrigerant oil can be
filled using the A/C service station for R134a.
Exception:
BMW i and hybrid vehicles (with an electric A/C compressor) that
are filled with R134a refrigerant/Sanden SP-A2 refrigerant oil. These
vehicles must be injected with Sanden SP-A2 refrigerant oil.
When filling the refrigerant circuit with R134a, always ensure you
use the correct, vehicle-specific refrigerant oil type!
The previous ND-8 refrigerant oil must not be mixed with Sanden
SP-A2 refrigerant oil!
In other words, the refrigerant oil ND-8 must not be filled in
refrigerant circuits which were filled with Sanden SP-A2 in the factory.
Sanden SP-A2 refrigerant oil may be mixed with ND-8 refrigerant

oil in vehicles without an electric A/C compressor.
In other words, the refrigerant oil Sanden SP-A2 must be filled in
refrigerant circuits which were filled with ND-8 in the factory.
However, this is permitted only in vehicles starting from F-series.
Note the overview of the refrigerant oil to be filled.
To prevent inadmissibly mixing the different refrigerant oil types,

rinse the A/C service station hoses after each drawing off/filling
procedure!
64 50 ... Safety information for handling refrigerant R1234yf
Warning!
Danger of injury!
Refrigerant circuit is under high pressure! Work on the refrigerant
circuit may only be carried out by experts!
Draw off refrigerant without fail BEFORE all repair work on the
The refrigerant circuit is depressurised AFTER drawing off.
The pressure gauge on the A/C service unit must be checked
for the actual pressure drop prior to repair work.
It is absolutely essential to read and observe the relevant
operating instructions for the A/C service unit used!
At high temperatures, R1234yf is inflammable!

Wear safety goggles
Do not smoke!
Observe country-specific safety regulations.
First aid measures:

Eye contact: In the event of contact with the eyes, rinse
immediately with plenty of running water and consult an
ophthalmologist.
Skin contact: In the event of contact with skin, remove affected
clothing immediately and rinse with plenty of water.
After inhalation: If refrigerant vapours are inhaled in greater
concentrations, remove the person affected to an area of fresh air
and keep them under supervision. Call for a doctor. If breathing
problems are experienced, breathe additional oxygen. If the person
affected is breathing with difficulty or has stopped breathing, incline
the person's head at the neck and administer the kiss of life.
32 1 270
hours.
E84, E89
Warning!
Important!
Warning!
is inflammable.
(high pressure).
station
damage.
Installation note:
Attention!
Note:
condenser (2-6).

64 52 ... Notes on changing the air conditioning compressor, determining the
amount of refrigerant oil (amount of refrigerant oil of new air conditioning
compressor not known)
Note:
This procedure only applies if the new air conditioning compressor
does not have a label with the amount of refrigerant oil.
A different procedure applies for air conditioning compressors with a label
indicating the amount of refrigerant oil.
Attention!
Risk of damage!
Remove the air conditioning compressor without
damaging and without the use of force!
Air conditioning compressors with plastic belt pulleys:
Avoid impacts/knocks to plastic belt pulley (caused by
tools, contact with base).
Return faulty air conditioning compressors in their
original packaging only and with sealed connected
branches.
Attention!
In the event of a mechanical air conditioning compressor
failure and the resulting ingress of chips into the
refrigerant circuit, replace the following parts:
Air conditioning compressor
Air conditioning condenser
Desiccant insert
Line to the air conditioning condenser
Refrigerant oil
The new air conditioning compressor is filled at the factory with

refrigerant oil.
The amount of refrigerant oil in the new air conditioning
compressor corresponds to the amount of refrigerant oil for the
entire new and unfilled refrigerant circuit.
When replacing the air conditioning compressor it is

absolutely essential to adapt the amount of refrigerant oil in
accordance with the instructions below!
An adjustment of the amount of refrigerant oil is not required in
the following case:
Replacement of the complete refrigerant circuit.
Draw off A/C system.
Note down the amount of refrigerant oil shown on the A/C service
station display.
When evacuating the air conditioning system, refrigerant oil is

also extracted and collected in the oil separator of the A/C
service station. This amount of refrigerant oil is displayed after
the extraction of the air conditioning on the display of the A/C
service station.
Transfer all of the refrigerant oil remaining in the previous air

conditioning compressor into a measuring cup via the oil filler plug.
Turn the belt pulley during the filling process. This allows more
refrigerant oil to flow out of the previous air conditioning
compressor.
Read the amount of refrigerant oil at the measuring cup.
Open oil filler plug. Tightening torque 64 52 2AZ.

Fill the entire contents of the new air conditioning compressor in a
clean collecting vessel.
Fill the same quantity of refrigerant oil (from the new air conditioning
compressor), as was drained from the present air conditioning
compressor, + 10 ml precautionary allowance in a clean measuring
cup and again fill it in the new air conditioning compressor . At least
but a total of 50 ml.
Example:
20 ml read at measuring cup:
20 ml + 10 ml precautionary allowance = 30 ml < 50 ml
determined amount of refrigerant oil for new air conditioning
compressor = 50 ml
The drained new refrigerant oil can be filled into the expansion
tank of the A/C service station after draining.
If the new, drained refrigerant oil is not filled straight away into the
expansion tank of the A/C service station, it must be disposed of
properly.
On account of its hygroscopic properties, refrigerant oil must

not be stored in open collecting vessels.
Reassemble the vehicle.

Evacuate Air conditioning.
Before filling the air conditioning with refrigerant, fill in the noted
quantity of refrigerant oil previously drawn off, into the system.
Fill A/C system.
Attention!
Risk of damage!
During initial operation of a new air conditioning
compressor, it is absolutely essential to carry out the
following breaking-in procedure.
Do not exceed idle speed.
Note:
The breaking-in procedure for the new air conditioning
compressor can be carried either manually or with the diagnosis
system.
Manual:
Switch off the air conditioning.
Set all ventilation outlets in the instrument panel to "OPEN".
Start engine and let it stabilise at idle speed.
Set the blower output to a minimum of 75% of the maximum blower
output.
Switch on the air conditioning and allow the engine to run at idle
speed for a minimum of 2 minutes.
Carry out the following service function with the diagnosis system:
Body
Heating and air conditioning functions
Run-in protection for A/C compressor
The refrigerant oil drawn off from the oil separator of the A/C service
station and from the previous air conditioning compressor must not
be reused and must be correctly disposed of.
Observe country-specific waste disposal regulations.
Installation note:
If the refrigerant circuit is open for longer than 24 hours:
Replace desiccant insert
Attention!
are used.
bonnet.

Europe Asia America

Herzegovina
Netherlands
Korea
Republic
models have R134a.

BMW i as of 09/2013
USA and Canada:
South Korea:
and model.

Attention!
Attention!
Exception:


procedure!
Warning!
Danger of injury!

Wear safety goggles
Do not smoke!
First aid measures:

ophthalmologist.
00 11 500 Checking/topping up fluid level in automatic transmission (A5S
360R / 390R, A4S 200R / 310R)
Important!
Use only the approved transmission fluid in this automatic
transmission.
Failure to comply with this requirement will result in serious damage to

the automatic transmission!
Details of approved fluid type,
refer also to adhesive label on transmission fluid sump.
Move selector lever to parking position ”P”.

The vehicle must be horizontal and secured against rolling off.
Note:
Picture shows transmission for vehicles with gasoline engines. The
filler plug is located at the front on vehicles with diesel engines and
on transmissions A4S 200R (GM4).
Connect BMW Diagnosis and Information System (DIS) or BMW MoDiC

to vehicle.
Undo oil filler plug (1).
Top up automatic transmission fluid until it flows over.
Screw in oil filler plug (1) by hand.
Start engine and run at idle speed.
Operate brake and, with engine at idle speed, change up and down all
gears several times.
Release oil filler plug (1) again.
Increase temperature of automatic transmission fluid to 30 ... 50 °C.
Interrogate temperature of automatic transmission fluid with MoDiC or
DIS.
Run engine at idle speed.
Screw in oil filler plug (1).
Installation:
Check sealing ring on filler plug (1) for damage and if necessary
replace sealing ring and filler plug.
00 11 ... Checking/topping up oil level in rear differential
Important!
Risk of damage!
To avoid serious damage to the rear differential, it is essential to
use only approved gear oils in the differential.

Check oil level.
If necessary, pour in rear differential oil up to lower edge of opening for oil
filler plug (1).
Installation:
A. Oil filler plug with sealing ring:
Replace sealing ring (1).
Tightening torque: 33 11 3AZ.
B. Oil filler plug with O-ring:
Replace oil filler plug (2).
00 .. . Notes on SMG transmission service functions
Note:
The service functions must be carried out in the relevant order!
When replacing SMG control unit 1. Teach in clutch valve characteristic values
2. Adapt complete transmission
3. Teach in clutch slipping point
4. Teach in offset of longitudinal-acceleration sensor
Before working on the hydraulic 1. Reduce hydraulic pressure
system, if the system:
- is to be opened
- is filled with hydraulic fluid
(depressurization of hydraulic
system)
After working on the hydraulic 1. Bleed actuator block
system, if the system was opened
2. Bleed clutch slave cylinder and hydraulic lines
After removal and reinstallation of 1. Teach in clutch valve characteristic values
parts (no replacement of parts!)
- Engine
- Transmission
- Clutch
When replacing transmission Note: Perform points 1 and 2 only if the hydraulic system was
opened.
When replacing hydraulic unit with
actuator block 1. Bleed actuator block
When replacing engine 2. Bleed clutch slave cylinder and hydraulic lines
3. Teach in clutch valve characteristic values
When replacing clutch Note: Perform point 1 only if the hydraulic system was opened.
4. Reset clutch curve (automatically carried out by BMW diagnosis
system after successful teaching in of points 3 and 4)
When replacing individual clutch parts: 1. Teach in clutch valve characteristic values
- Release lever 2. Teach in clutch slipping point
- Ball pin 3. Reset clutch curve (automatically carried out by BMW diagnosis
- Release bearing ...
When replacing clutch slave cylinder 1. Bleed actuator block
with PLCD sensor
When replacing longitudinal- 1. Teach in offset of longitudinal-acceleration sensor
acceleration sensor
00 11 239 Oil change in automatic transmission (A4S 310R / 270R)
Note:
Transmission at operating temperature.
The vehicle must be on level ground.
Apply parking brake.
Automatic transmission fluid,
refer to BMW Service Operating Fluids.
Unfasten drain plug.Installation:

Tightening torque,
refer to Technical Data 24 11 6AZ
Version with dipstick:

Tilt handle and remove dipstick.
With special tool 24 0 080 top up with automatic transmission fluid.

Query transmission oil temperature with MoDiC or BMW Service Tester
(refer to Troublshooting Manual).
Note:
Never wipe off oil dipstick with a cloth which loses lint.
Start engine.
Apply brake and run through all driving stages several times in neutral.
Move selector lever into position ”P”.
Determine oil level (H) with dipstick.
Using following table, correct oil level by draining or topping up.
Oil temperature + ° C Oil level (H) mm Min . . . Max

20 3 . . . 15
25 5 . . . 17
30 8 . . . 20
35 11 . . . 22
40 13 . . . 25
45 14 . . . 26
50 16 . . . 27
55 17 . . . 28
60 19 . . . 29
65 21 . . . 32
70 22 . . . 34
75 24 . . . 36
80 26 . . . 38
85 29 . . . 41
90 31 . . . 43
Version without dipstick:

Unfasten filler screw.
Installation:
Tightening torque,
To top up, attach filler neck (2) to filler aperture.
Top up automatic transmission fluid until it overflows.
Screw in filler screw.

(refer to Troubleshooting Manual).
Start engine.
Transmission temperature between 30 ... 55°C.
Unscrew filler plug (1).
Correct oil level by draining or topping up until it overflows.
00 11 229 Oil change in manual transmission
Note:
Gearbox must be at normal operating temperature.
Gear oil:
Refer to BMW Service Operating Fluids.
Filling capacities:
Refer to Technical Data.
Draining gear oil:

Release oil drain plug (1) and filler plug (2).
Clean oil drain plug (1) and screw in.
Fill transmission with ATF.
Pour in gear oil until overflowing.
Tighten in filler screw (2).
00 11 259 Oil change in rear differential incl. used oil disposal
Note:
Observe following instructions and torques for variants (A & B).
A. Replace sealing ring (1) after releasing.
Tightening torque 33 11 3AZ (with sealing ring).
B. Replace screw plug (2) with O-ring after releasing.
Tightening torque 33 11 9AZ (with O-ring).
Warning!
Risk of burning if exhaust system is touched!
Important!
Risk of damage!
To avoid serious damage to the rear axle differential, it is essential
to use only approved transmission oils in the rear axle differential.
Note:
The oil does not need to be changed in rear differentials carrying the
”Life‐Time‐Oil” sticker.
Only change oil when rear differential is at normal operating temperature.
Recycling:
Catch and dispose of emerging differential oil.
Observe country-specific waste-disposal regulations
Oil drain plug present:

Place oil collecting apparatus underneath.
Open plug (1).
Drain and dispose of differential oil.
Replace sealing ring or screw plug.
Open plug (2).

Add rear differential oil up to lower edge of opening for screw plug (2); if
necessary, refer to Technical Data for necessary fill quantity.
No oil drain plug:
Open plug (1).
00 00 249 BMW engine oil service (M47)
(Change engine oil and oil-filter insert)
Caution!

malfunction.
Note:
socket only. When the main flow oil-filter cover is released, the oil
flows from the oil-water heat exchanger back into the sump.
Release main flow oil-filter cover and remove towards top.Installation:

Tightening Torque,
Installation:

Open cover in engine underguard.
Open oil drain plug or drain off oil.
Installation:
Tightening Torque,
Top up engine oil.

00 00 249 BMW engine oil service (M47TU)
Caution!

malfunction.
Note:
Do not damage main flow oil filter cover, release and tighten down
with a socket only. When the main flow oil filter cover is released,
the oil flows from the oil-water heat exchanger back into the sump.

The tightening torque of 25 +5 Nm is stamped in the cover.
Installation:

Open cover in reinforcement plate.
Open oil drain plug or draw off oil through guide tube for oil dipstick.
Installation:
Fill system with engine oil.

If necessary, top up engine oil.
00 00 250 BMW engine oil service incl. supplementary service (M57 / M47TU)

Reset service interval indicator according to factory specification.
Replace microfilter for interior ventilation.
Check brake lining thickness.
Adjust handbrake cables.
Caution!
Otherwise the alternator may malfunction.
Note:
with socket only. When the main flow oil filter cover is released, the
oil flows from the oil-water heat exchanger back into the sump.
Release main flow oil filter cap and remove towards top.Installation:
Installation:
Withdraw oil-filter element towards top.Installation:

Press oil-filter element onto support in oil-filter housing.
Open cap in engine underguard.
Open oil drain plug or draw off oil.
Installation:
Note:
Illustration from M57.
Top up engine oil.

11 00 039 Checking compression in all cylinders (M47 / M57 / M47TU)

11 0 222
11 0 236
Warning!
On cars with manual transmissions, make sure the car is not in gear
during the starting procedure!
Caution!
M57/M47TU only:
To prevent the injectors from injecting, it is necessary to disconnect
the injector plug connections.
Only M47:
The fuel pump relay must be removed in order to prevent fuel from
escaping.
All intake ducts must be open.

If necessary, remove covers, cloths or similar.
Remove all glow plugs.
Screw special tool 11 0 236 into bores of glow plugs.

Screw special tool 11 0 222 onto special tool 11 0 236 .
Actuate starter motor until display has reached maximum value.
Assemble engine.
Note:
Read fault memory of DDE control unit.
Check stored fault messages.
Rectify faults.
Now clear the fault memory.
Headaches
Dizziness
Stomach aches
Vomiting
Diarrhoea
Cramps/fits
Unconsciousness

or mugs)
First aid measures:

immediately.
Engine identification
Engine number at the marked surface.

Replacement drives are already assigned a number containing the
identification and engine number at the factory.
The old drive number must be imprinted for replacement crankcases.
Magnesium crank cases feature a label, the engine number does not
need to be embossed.
M47 / M47TU / M47T2
M57 / M57TU / M57T2
M67 / M67TU
N47 / N47S / N47C / N47T / N57 / N57S / N57T
M52 / M52TU
M54
M56
N20 / N26
N40 / N45 / N45T / N43
N42 / N46 / N46T
N51 / N52 / N52K / N52T / N53 / N54 / N55

N62 / N62TU
Position (1) engine number.

PositionÂ (2) engine code letters.
N63, N63O1. N63O2
S63
N74, N74O1,
S63T0 to engine number 2001 0052 on right side cyl. 1-4.
S63T0 from engine number 2001 0053 on left side cyl.l 5-8.
E72 Vehicles must be imprinted on the left side cyl. 5-8.
N73
S54
S85 / S65
S55
W10 / W11
W16
W17
W20
N12 / N13 / N14 / N16 / N18
B37 / B38A / B47 / B48A

in the area of the oil sump
B38B / B48B
B38
B57
B58
Assemble engine.
11 00 300 Engine oil consumption measurement
Attention!
This procedure for measuring oil consumption may not be used for the S 85 due to the oil pan design.
Many complaints about oil consumption are caused by the oil level being measured using the wrong method.
The oil consumption should be measured after a distance of 7,500 km at the earliest, as the process of running
in the engine will not have been essentially completed and the engine oil consumption stabilised until this
distance has been covered.
Engine oil consumption that may occur in an engine can only be determined by the customer on the basis of
the refilled engine oil quantity. As soon as the engine oil level falls below the MAX mark on the dipstick, many
customers top up the engine oil without paying attention to a number of basic rules, such as the vehicle must
be standing on level ground, a certain period of time must be left to allow the oil to flow back to the sump. In
such cases, the available container sizes (e. g. 1-litre can) make it easy to top up above the MAX mark. Too
much added engine oil is damaging to the engine and is consumed more quickly due to the splash effect.
It is therefore recommended to allow the engine oil level to the MIN mark and only then to add the required
engine oil quantity. The distance between the marks is equivalent to approx. 1.0 to 1.5 litres.
available (see below).
Measuring oil consumption by weighing:
To assess a warranty or goodwill claim, only the following oil consumption measurement method by weighing
can be accepted (this must have been carried out by a BMW contractual partner):
Note:
The engine must not leak any oil.
Engine oil may only be drained off when the engine is at its normal operating temperature. The engine
oil temperature must be at least 90 °C and read off on the diagnosis system.
Preparation:
1. Eliminate any leaks and traces of oil before measuring the engine oil consumption.
drop below 90 °C.
housing).
8. Retighten the primary flow oil filter.
9. Pour in the specified engine oil quantity for the engine type in question (with filter change).
10. Drive the vehicle for a distance of at least 1,000 km/500 miles. Increasing the mileage will produce
significantly better measuring results.
Measurement procedure:
11. Check the engine for leaks; if the engine is not tight, the examination will not be meaningful.
12. Prepare the measuring container to be able to capture the oil quantity.
drop below 90 °C.
housing).
19. Weight the amount of drained engine oil. (Engine oil has a density of about 0.86 g/cm³ at room
temperature.)
Amount of oil added (cm³) ‐ amount of oil drained off (g): 0.86 g/cm³
Engine oil consumption = —————————————————————————————
mileage reading when draining - mileage reading when adding engine oil
Example:
Volume of oil added at mileage reading 44,800: 4.000 cm³
Weight of oil added at mileage reading 45,900: 2.700 g
4.000 cm3 - 2.700 g : 0.86 g/cm³

Engine oil consumption = —————————————— = 0.78 cm³/km
45,900 km - 44,800 km
0.78 cm³/km = 0.78 l/1,000 km
Test certificate for engine oil consumption:
Vehicle data: _____________________________

BMW (type): _____________________________
Chassis number: _____________________________
Added oil quantity (in ccm): _________________ at kilometre reading:__________

ccm
less drained off oil quantity (in g) : 0.86 _________________ at kilometre reading:__________
(g/ccm) ccm
=> oil consumption: _________________ => mileage: _____________________
ccm km
Oil consumption [l/1000 km] =

_____________ [ccm] oil consumption _____________ [km] mileage
Oil consumption after balancing out: ____________________________ l/1000 km

Oil grade: ____________________________
Oil grade: ____________________________
Viscosity: ____________________________
Cause of damage: ____________________________
___________________________________ ___________________________________
Dealer address Signature
11 00 ... Engine oil consumption measurement
Procedure for engine oil consumption measurement, see following

documents:
Engine oil consumption measurement (all without S85)
Engine oil consumption measurement (only S85 with one oil drain
plug)
Engine oil consumption measurement (only S85 with two oil drain
plugs)
Record on oil consumption measurement
11 . . . . . Equipment recoding special tool number of the transverse
member for fixing the engine in the installation location
Equipment recoding from 00 0 200 to 00 6 0 000
Designation Special tool new Special tool previous

Cross-member, previous --- 00 0 200
Cross-member, new 00 6 000 ---
Mounting bridge 00 6 001 00 0 201
Spindle with hook 00 6 002 00 0 202
Extension 00 6 003 00 0 203
Adapter support 00 6 004 00 0 204
Extension 00 6 005 00 0 205
Chain with hook 00 6 006 00 0 209
Set of supports 00 6 010 00 0 206
Set of supports 00 6 020 00 0 207
Set of supports 00 6 030 00 0 208
Connector 00 6 031 ---
Profile strip (2 x) 00 6 032 ---
Supports (4 x) 00 6 033 ---
Set of supports 00 6 040 ---
Profile strip 00 6 041 00 0 451
Supports (2 x) 00 6 042 00 0 452
Supports, short (2 x) 00 6 043 ---
Supports, long (2 x) 00 6 053 ---
Support, long 00 6 060 ---
Supports (2 x) 00 6 070 ---
11 00 ... Handling components after flood damage
Flood damage can occur if the permissible fording depth of a vehicle is exceeded. Ingress of water can cause
damage to the engine (water shock) or components.
Because dirt particles generally enter into the component with the water (e.g. starter motor, wiring harness),
the components need to be thoroughly inspected.
Residual moisture in the components leads to corrosion (increased contact resistance in the component),
which can lead to a component failure at a later time.
If water ingress into the electrical components cannot be ruled out, it is recommended to replace the
component to ensure correct functioning through the vehicle lifetime.
11 00 ... Overview of consumables (Electronic Parts Catalogue)
1.0 Sealing compound for injection.
Repair Designation, Electronic Part number, Electronic Application examples

instructions Parts Catalogue Parts Catalogue
(engine)
1.1 S55, S65, S85 Loctite 171000 primer 83 19 7 515 683 For hardening Loctite 193140
sealing compound
1.2 S55, S65, S85 Loctite 193140 liquid 83 19 0 439 030 Sealing between crankcase
sealing compound upper and lower halves
1.7 W20 Dow Corning liquid 07 58 0 397 777 Sealing between crankcase
sealing compound upper and lower halves
Sealing of oil sump
2.0 Sealing compound for application.
Designation in repair instructions Designation, Part Application examples

Electronic number,
Parts Electronic
Catalogue Parts
Catalogue
2.1 M41, M47, M47TU, M47T2, Drei Bond 07 58 9 062 For sealing junction
1209 liquid 376 points on crankcase
M50, M51, M52, M52TU, M54, sealing
compound
M57, M57TU, M57T2,
M60, M62
N12, N14, N16, N18
N20, N26
N40, N42, N45, N45N, N46, N46N, N43,
N47, N47top, N47C N47D1
N51, N52, N52N, N53, N54, N55,
N57, N57T,
N62, N62TU, N63, N63O1
N73, N73H, N74
S14, S38, S50, S52, S54, S62, S65, S85
2.2 N12, N13, N14, N16, N18, N20, N26, N40, N42,N43, Loctite 5970 83 19 0 404 Sealing between
N45, N46, N51, N52, N53, N54, N55 liquid sealing 517 crankcase upper and
compound lower sections.
W10, W11, W16,
2.2 N47top, N47D1, N47C1 Loctite 5970 83 19 0 404 Timing case cover
liquid sealing 517 sealing, oil sump,
N57D1 N57S1, compound coolant pump,
component carrier.
B32 ,B36 ,B37 ,B38 ,B42 ,B46 ,B47 ,B48 ,B57 ,B58
2.3 N12, N14, N16, N18 Loctite 648 07 58 9 067 Sealing between the
liquid sealing 732 seal plug and
W16 compound crankcase
2.4 N12, N13, N14, N16, N18 Loctite 83 Sealing between
121078 liquid 19 2 223 765 cover sleeve and
W16 sealing crankcase
compound
3.0 Cleaning agent.
Designation in repair Designation, Electronic Part number, Electronic Application examples

3.1 N12, N13, N14, N18, Cold cleaner (chlorine 83 19 0 026 956 Cleaning assemblies,
N20, N26, free) washing engine
N45, N46, N45T, N46T,
N43,
N51, N52, N52Kp,
N52TU, N53, N55,
N63, N63S, N63 Hybrid,
N63O1, N63O2
N73, N74
B37, B38 B47, B48, B58
3.2 M47, M47T1 M47T2, Universal cleaner 83 19 2 360 981 Clean intake pipe.
M57 M57T1, M57T2
N47 K/U/O/T 0/1
N47C
3.3 All Brake cleaner 83 19 2 365 214 Clean.
4.0 Lubricant for application.
Designation in repair instructions Designation, Part number, Application examples

Electronic Electronic
Parts Parts
Catalogue Catalogue
4.1 N12, N13, N18, N20, N26, N42, N46, Lubricating 83 19 2 160 340 For greasing the splined
N46TU, N51, N52, N52KP, N52TU, N55, grease shaft on actuator
N62, N62TU, N63O0, N63O1, N63O2, N73 Longtime PD1 drive/gearing of
intermediate shaft.
S55, S63T0
B38, B48, B58
4.2 M47, M47TU, M47T2, M57, M57TU, M57T2, High- 83 23 0 309 003 For greasing the thread on
temperature the exhaust turbocharger.
assembly
paste
4.3 N12, N13, N14, N16, N18 High 83 19 2 158 851 For greasing the threads
temperature on the oxygen sensors.
N20, N26, paste 83 19 2 158 852
N40, N42, N45, N45TU N46, N46TU, N43.
N51, N52, N52Kp, N52TU, N53, N54, N55.
N62, N62TU, N63O0, N63O1, N63O2
N73, N73H, N74.
S63T1, S65, S85.
B38, B48, B58
4.4 N47, N47O1 N47C1, N47T N47D1 Copper paste 81 22 9 400 794 For greasing the double
hex head bolt on the
N57 N57D1 exhaust turbocharger.
N63O0, N63O1, N63O2 For greasing the central
bolt on the VANOS gear.
S63, S63T0
4.5 M47, M47TU, M47T2 High- 83 23 0 441 070 For greasing the injectors
temperature or injector shafts.
M57, M57TU, M57T2 grease
(UrethynE2 ). Solenoid valve and piezo
N47, N47O1 N47C1, N47T N47D1 injector.
N57 N57D1
4.6 N47T0, N47T1 Assembly 83 29 9 407 778 For lubricating the O-rings
paste of the pressure pipes.
N57T0, N57T1, N57S1
Multistage turbocharging
B47T0, assembly.
4.7 W20 Assembly No longer For greasing the torsion
paste, grease greased. splined shaft.
4.8 N63O1, N63O2 Assembly 83 23 9 407 778 For greasing the central
paste, grease bolt on the crankshaft.
4.9 W20 Assembly 83 23 9 407 778 Grease O-ring on
paste, grease alternator.
5.0 lubricant for filling
Designation in repair Designation, Part number, Application examples

instructions Electronic Parts Electronic Parts
Catalogue Catalogue
5.1 M47, M57 Exhaust turbocharger 83 19 2 362 168 For filling the exhaust
additive turbocharger after the
renewal.
5.2 B32, B36, B37, B38, Exhaust turbocharger 83 19 2 457 276 For filling the exhaust
B42, B46, B47, B48, B58 additive, petrol MSP turbocharger after the
renewal.
6.0 Lubricants to loosen locked screw connections.

Catalogue Catalogue
6.1 M47, M47TU, Brunox lubricating 83 23 0 418 567 For releasing the glow elements.
M47TU2, M57, grease
M57TU, M57TU2.
N47, N47C, N47D1,
N57, N57D1, N57S1
W16, W17,
B37, B47, B57
6.2 E89 Brunox lubricating 83 23 0 418 567 For releasing and tightening the
grease screw connection of the rubber
F10, F11. mounts.
7.0 Leak detection spray and contact spray

Catalogue Catalogue
7.1 Petrol: Leak detection spray 83 19 9 407 861 Check charge air path for
tightness.
N13, N20, N26,
Example: leakage on charge
N54, N55 air hose or charge air cooler.
B38, B48, B58
Diesel fuel:
M47, M47TU, M47TU2,
M57, M57TU, M57TU2.
N47, N47C, N47D1,
N57, N57D1,
B37, B47
7.2 S55 Contact spray 81 22 9 400 208 For cleaning and protecting of
electrical plug connections.
11 00 050 Removing and installing engine (M47)
Follow instructions for disconnecting and connecting battery,

refer to General Information in MG 12.
Disconnect negative battery lead.
Disconnect positive lead at terminal in engine compartment.
Remove transmission,
refer to 23 00 023.
Caution!

malfunction.
Caution!
If the charge air hoses are not fitted without grease and dry, this will
result in supercharger failure.
Fit charge air hoses without grease and dry.
Lift engine hood into assembly position.

Note:
The following work must be carried out with a second person
assisting. Work instruction applies to left and right sides.
Gently raise retaining clip and simultaneously push upwards.
Hold engine hood, unhook damper on hood.

Slide special tool 51 2 160 over damper.
Open engine hood completely and reconnect damper with special
tool 51 2 160 to hood.
Drain and dispose of coolant.Installation:
Replace seal.
Tightening Torque,
Vent cooling system and check for leaks,
refer to 17 00 005.
Remove radiator blind,

refer to 17 11 020.
Remove pressure hose between turbocharger and intercooler.
Caution!
If necessary, remove compressor for air conditioning (lines remain

connected).
Remove intake air manifold,
refer to 11 61 050.
Unclip vacuum line from brake booster.
Remove filter element.Installation:

Install cleaner insert with support (1) downwards.
Unfasten engine section of wiring harness and place to one side with
cable duct.
This work is described in Replacing engine section of wiring harness,
refer to 12 51 001.
Remove alternator drive belt,
refer to 11 28 010.
Disconnect fuel feed and return lines from fuel filter. This work is
described in Replacing fuel filter unit,
refer to 13 32 061.
Remove vane pump from timing case cover (lines remain connected),
refer to 32 41 060.
Pull lock and detach water hoses from coolant thermostat and EGR
cooler.
Installation:
Refer to general instructions for work on cooling system.
Detach water hoses from heater.
Release lower water hose (1) at double pipe on rear cylinder head.
Fit engine to special tool 11 0 070.

Unscrew earth strap from carrier on right-hand side.
Unfasten top and loosen bottom right and left engine mounts.
Lift out engine.

11 00 050 Removing and installing engine (M47TU)

11 0 070
51 2 160
Observe instructions for disconnecting and connecting battery.

Refer to general information in MG12.
Disconnect negative battery lead.
Disconnect positive lead at terminal in engine compartment.
Remove transmission.(Manual transmission)
Remove transmission.(Automatic transmission)
Caution!

malfunction.
Caution!
Lift engine hood into assembly position.

Note:
The following work must be carried out with a second person
assisting. Work instruction applies to left and right sides.
Gently raise retaining clip and simultaneously push upwards.
Hold engine hood, unhook damper on hood.

Slide special tool 51 2 160 over damper.
Open engine hood completely.
Reconnect damper to engine hood with special tool 51 2 160 .
Replace seal.
Vent cooling system and check for leaks.
Installation:
Remove fan cowl.(Manual)

Remove radiator blind.(Automatic)
Remove intake air manifold.

Note:
EGR valve can remain on manifold.
(Release clamps on pressure pipe and on EGR pipe/radiator.)

Release vacuum hoses on vacuum reservoir.
Detach vacuum hose from EPPT for turbocharger.
Detach plug from EPPT for turbocharger.
Release cable on auxiliary heater.
Detach vacuum line from brake booster.
Unfasten screws.
Release air funnel in direction of arrow and remove.
Release screw (1).

Slacken screw (2) and turn flange in direction of arrow.
Release opposite side at quick-release coupling.
Remove pressure pipe between turbocharger and intercooler.
Detach plug from pressure pipe between intercooler and EGR valve.
Remove pressure pipe between intercooler and EGR valve.
Installation:
Quick-release couplings must snap audibly into place.
Remove alternator drive belt.
Remove power steering pump from timing case cover and place to one
side.
(Lines remain connected)
Note:
If fitted:
Remove A/C compressor and tie back to one side.(Lines remain

connected, filling is retained).
Remove coolant hose between thermostat, EGR cooler and radiator.
Release coolant hose on distributor pipe at bottom.

Place hose to one side.
Release coolant hoses on connection to engine block.

Place tube to auxiliary heater to one side.
Release heater connection on bulkhead.
Installation: Quick-release couplings of coolant hoses must snap

audibly into place.
Disconnect fuel feed and return lines (1/2).
Release screws (1).

Remove cover from electronics box.
Detach sealing strip (1).

Detach bracket (2).
Detach profile seals (3) with wiring harnesses.
Release panel (4).
Detach profile seal (5) with wiring harness.
Disconnect plug connection on DDE 5 control unit (1).
Disconnect plug connections on transmission control unit: module 4 (2)
and module 2 (6).
Detach relay for reversing light (RFL) (3).
Release relay for Digital Diesel Electronics (DDE) (4).
Detach engine fuse with socket (5) from equipment carrier.
Release engine plugs (7, 8).
Disconnect ground cable from terminal (1).

Release rubber grommets affected.
Remove ”wiring harness section for engine” from electronics box and
place on engine.
Fit engine to special tool 11 0 070 .
Unscrew earth strap from carrier on right-hand side.

Unfasten top and loosen bottom right and left engine mounts.
Lift out engine.

Danger of injury!
Impaired sight

First aid measures:

Warning!
Recycling:

ground.
11 12 729 Check cylinder head for watertightness (M47TU / M47T2)

11 6 400
11 6 401
11 6 406
11 6 407
11 6 408
(cylinder head dismantled)
Seal off coolant openings with special tool kit 11 6 400 .

Special tools required from kit: 11 6 401 , 11 6 406 , 11 6 407 , 11 6 408 .
Note:
Special tool 11 6 407 consists of 14 screws for mounting special
tools 11 6 401 to cylinder head.
Immerse cylinder head in a water bath.

Test pressure: 4.5 bar.
Check cylinder head for discharges of air and thus for existing crack
formations.
Note:
Use water whose surface tension has been reduced with flushing
agent.
11 12 595 Checking a valve guide for wear (M47 / M47TU)

00 2 510
(valve removed)
To measure the tilt clearance, insert a new valve so that the valve stem
end terminates at the valve guide.
Fit special tool 00 2 510 (dial gauge) and measure tilt clearance.
Max. permissible tilt clearance.
Note:
If the tilt clearance is too great, the cylinder head and the valves
must be replaced.
11 12 729 Checking cylinder head for water leaks (M47)
(Cylinder head dismantled)
Seal coolant openings with special tool kit 11 6 400 consisting of special
tools 11 6 401/403/405/406/407.Note:
Special tool 11 6 407 is a set of screws (14 pieces) for securing
special tools 11 6 401/402 to cylinder head.
Immerse in a water bath.

Test pressure: 4.5 bar.
Check cylinder head for escaping air (cracks).
Note:
If necessary, relieve water bath with cleaning agent.
11 12 800 Cleaning cylinder heat intake channels and intake plenum (M47,
M57)

11 2 300
11 5 180
11 6 080
2 356 969
2 356 970
2 356 968
2 356 967
2 356 966
00 9 120
11 6 480

Clamp off battery
Remove intake plenum
Detach the injector wiring harness from the cylinder head
cover
Remove the electric fan if necessary
Cleaning intake plenum:
Wear safety goggles and protective gloves.
Attention!
Electric swirl-flap controller must not be removed!
Never place electrical components in cleaning bath!
Do not place pneumatic swirl-flap controller in cleaning bath!
Dismantle the intake plenum (remove exhaust-gas recirculation valve,

throttle valve, pneumatic swirl-flap controller and charging pressure
sensor).
Prepare cleaning bath with 1 part BMW universal cleaner (see Section
3.2) and 2 parts water.
Place intake plenum in cleaning bath. Leave to soak at least 1 hr.
Note: Place the intake plenum in the cleaning bath so that the
electric swirl-flap controller is not lying in the bath.
Crank engine to cylinder no. 1 TDC setting:
Unlock and disconnect plug (1) as required.
Loosen screw.
Remove pulse sensor (2).
Installation note:
Check sealing ring (1) for damage and replace if necessary.
Note:
Shown with cylinder head cover removed for enhanced clarity.
Figure M57TU.
Attention!
Do not crank engine in reverse direction.
Look through camshaft position sensor opening or oil filler cap opening to
conduct visual inspection.
Crank engine at central bolt.
The cam lobes (1) on the intake camshaft (E) at no. 1 cylinder point to
the right as viewed toward the front when engine is at TDC setting.
Remove protective cap in direction of arrow.Installation note:

Reinstall protective cap with some grease.
M47, M47TU, M57, M57TU:
Use the central bolt to turn over the engine, rotating the crankshaft in the
normal direction of rotation, continuing until the piston in no. 1 cylinder is
at TDC setting.
Secure the flywheel in the TDC setting with special tool 11 2 300 .
Special tool must be removed before starting the engine.
M47T2, M57TU2:
Use the central bolt to turn over the engine, turning crankshaft in the
normal direction of rotation, and continuing until the piston in no. 1
cylinder is at TDC setting.
M57T2, M57T2SCR:
Crank engine at central bolt in direction of rotation until piston of 1st
cylinder is in TDC setting.
Secure the crankshaft in the TDC setting with special tool 11 6 080 .
Attention!
Do not turn the engine back.
Special tool 11 6 080 must be removed before starting the engine.
Cleaning intake ports: Attention!

Risk of engine damage!
The intake valves of the corresponding cylinder must be closed
when cleaning the intake ports.
Start with the 1st cylinder when cleaning the intake ports.
The following are required:
Blasting tool 81 29 2 208 034
Walnut shell granulate
Vacuum cleaner
Attention!
Front area of sensors is marked with two notches. These can
additionally be highlighted in colour.
During the blasting process, only pull the wands out of the vacuum
adapter until the mark becomes visible.
Blasting wand for tangential swirl port:

2 356 969
Blasting wands for swirl port:
2 356 970 with straight outlet
2 356 968 with lateral outlet
Vacuum adapter for tangential swirl port:

2 356 967
Vacuum adapter for swirl port:
2 356 966
Note:
Use 2 litres of granulate per cleaning operation; this corresponds to a
blasting duration of approx. 20 seconds.
Open blasting tool (1) and pour in 2 litres of granulate (2).

Close the device again.
Note:
Operating pressure 6 - 8 bar.
Close main valve (1) on blasting tool (2).

Connect compressed air (3).
Cleaning the tangential swirl port of 1st cylinder:

Screw together blasting wand 2 356 969 (1) and actuator (2).
Note:
Actuator (3) has two stages!
In stage one, only compressed air flows through the blasting wand.
In stage two (operation is fully pressed), granulate is added (blasting
process).
Attention!
Danger of injury!
Risk of damage!
Second person required to assist.
Blasting wand may only be pulled out until the mark becomes
visible.
Wear safety goggles.
Connect vacuum cleaner (1) to vacuum adapter 2 356 967 (2). Hold
vacuum adapter 2 356 967 against swirl port at no. 1 cylinder.
Open the main valve on the blasting tool and switch the vacuum cleaner
on.
Insert blasting wand (3) into the adapter (2).
Open the actuator valve (4).
Slide locking lever (1) to the front in direction of arrow.
Operate compressed-air valve (2) at stage one; compressed air can now
flow in.
Fully operate valve (3) at stage two; walnut shell granulate is now
injected.
Clean intake port, rotating the blasting wand and moving it vertically up
and down.
Blasting wand may only be pulled out until the mark becomes visible.
When you notice that the container is becoming empty, continue
operation for at least 10 seconds at stage one in order to swirl up and
draw off the remaining granulate.
Close main valve, check pressure drop at the pressure gauge.
If necessary, evaluate the result (recommendation: endoscope or similar
device).
If necessary, repeat procedure.
Cleaning the swirl port of 1st cylinder:

Attention!
Risk of damage!
Plastic section (1) of the swirl port must not be blasted.
Before blast-cleaning, mechanically clean the plastic section of the swirl

port (1) in the cylinder head cover (e. g. using a plastic scraper, brushes
83 19 2 298 237 or similar tools).
Note:
Two blasting wands must be used for the swirl port.
This means that two individual cleaning operations are necessary.
Attention!
Danger of injury!
Risk of damage!
visible.
Swap over vacuum adapter 2 356 966 (1) and blasting wands (2).
Carry out one complete cleaning operation (identical to that for cleaning
the tangential swirl port) with blasting wand2 356 968 and then one
complete cleaning operation with blasting wand 2 356 970 .
To prevent damage to the cylinder head cover, the blasting wand should
never be pulled out further than the marking!
device).
Check that there is no granulate residue in both intake ports; if
necessary, draw off/blow out.
Cleaning the other cylinders:

Attention!
Remove special tool for securing the crankshaft.

Proceed in the standard firing order while using the same procedure to
clean the swirl ports at the remaining cylinders.
Firing order:
1 3 4 2 (4-cylinder engine)
1 5 3 6 2 4 (6-cylinder engine)
During this operation use 00 9 120 and 11 6 480 to turn the central bolt
180° (4-cylinder engine) or 120° (6-cylinder engine).
Remove the intake plenum from the cleaning bath.

Clean plenum openings and swirl flaps with brush set (1) part
number: 83 19 2 298 237.
Use brust set to clean the throttle valve, exhaust-gas recirculation valve
and the mounted parts.
Attention!
Do not clean electrical components with a component washing
machine or high pressure cleaner.
Protect electric swirl-flap controller against splashing water as
necessary!
Cover electric swirl-flap controller appropriately as necessary!
Then clean the plenum with a parts washer or a high-pressure cleaner.
Crank motor at central bolt at least twice.

Assemble engine.
Reset correction values at
Reset service function - 01 drive - DDE - Reset correction values of
injectors.
11 12 504 Disassembling and assembling cylinder head (M47 / M47TU)

00 1 450
11 0 192
11 0 342
11 0 343
11 1 045
11 1 065
11 1 067
11 1 442
11 3 131
11 3 132
11 3 136
11 3 346
11 6 050
(cylinder head removed)
Caution!
The glow plugs protrude at the sealing face and may be damaged
when the cylinder head is put down.
Remove glow plugs with special tool 11 6 050 .

If necessary, drill out special tools 11 6 050 which were supplied before
4/98 to 9.5 mm dia. 20 mm deep.
Installation:
Remove hydraulic valve clearance compensating elements and put

down in an orderly fashion.
Remove thermostat.
Remove coolant temperature sensor.
Unfasten nuts and remove exhaust manifold.Installation:
Replace seals.
Note arrangement of heat protection shields and seals. Tab
washers face outwards.
Coat stud bolt threads with copper paste -CRC-.
Replace nuts.
Tightening sequence from inside to outside!
Secure special tool 11 1 442 (additional bracket) to special tool 11 1 065

(assembly frame).
Secure special tool 11 1 065 (assembly frame) to special tool 00 1 450

(assembly stand).
Provide special tools for disassembly of cylinder head:
special tool 11 3 131
Special tool 11 1 067

Assemble special tools.
Lay special tool 11 3 136 (rubber mat) to protect valves against damage
on special tool 11 3 132 .
Caution!
Do not damage sealing surface of cylinder head.
Cover special tool 11 1 065 (assembly frame) in area (1) of cylinder head
seat with insulating tape or similar material.
Position cylinder head on special tool 11 1 065 and secure with

commercially available M10 screws (1).
Remove all valve stem seals 11 34 560.
Remove valves downwards and put down in an orderly fashion.
11 12 500 Removing and installing cylinder head (M47 / M47TU)

00 1 450
11 3 350
11 8 040
(engine removed)
Remove engine support frame on right.

Secure engine with special tool (mounting plate) 11 8 040 to special tool
(assembly stand) 00 1 450 .
Note:
Special tool 11 3 350 (mounting plate) can also be used after
reworking.
The subsequent procedure is described in the sections Removing and

installing camshafts and
Removing and installing cylinder head.
11 12 100 Removing and installing cylinder head (M47)
Remove battery cover.

refer to General Information MG 12.
Disconnect negative lead from battery.
Caution!

malfunction.
Disconnect intake air manifold,

refer to 11 61 050.
Remove injection nozzles,
refer to 13 53 320.
Remove cylinder head cover,
refer to 11 12 000.
Unfasten exhaust turbocharger from exhaust manifold.Installation:

Replace seal.
Coat thread with copper paste -CRC-.
Tightening Torque,
Drain and dispose of coolant,

refer to General Information for working on cooling system.
Installation:
Replace seal.
Tightening Torque,
Fill cooling system, vent and check for leaks,
refer to 17 00 005.
Remove EGR cooler,
refer to 11 71 100.
Note:
Thermostat for EGR cooler does not have to be removed.
Pull lock (1) and detach water hoses.Installation:

Release screw on coolant connecting line.Note:

Screw with M7 thread.
Installation:
Install screw and tighten down.
Tightening Torque,
Disconnect intake pipe from EGR valve.

Unscrew bolt (1).
Pull lock (2) and detach water hose.
Remove coolant connecting line.
Note:
Remove double pipe from cylinder head only, hoses remain
connected.
Release double pipe on side of cylinder head.

Release retaining screw (1) for double pipe at rear of cylinder head.Note:
Retaining screw (1) is between the hoses.
Release engine section of wiring harness, remove cable channel from

retainer and lay to one side.
Removal:
Removal of cylinder head is described separately from installation.
Assembly sequence for removal and installation is different.
Remove camshafts,
refer to 11 31 001.
Caution!
These screws must ”not” be removed.
Remove suspension element from cylinder head.

Remove bearing pin (1) for sliding rail.Note:
The sliding rail is guided and secured at a bearing pin and is only
removed later because of better accessibility.
Remove bearing pin (1) for tensioning rail.

Lift out tensioning rail (2) towards top.
Release screw (1) between timing case cover and cylinder head.Note:
Screw (1) is sealed with a sealing ring.
Release screw connection to timing case cover.

Note:
The hydraulic valve clearance compensating elements (HVA) can
fall out when the cylinder head is later put down.
If necessary, remove hydraulic valve clearance compensating
elements and put down in an orderly fashion.
Unfasten cylinder head bolts from outside to inside in following

sequence 10 ... 1.
Caution!
The glow plugs protrude at the sealing face and may be damaged
when the cylinder head is put down.
Remove cylinder head and put down so that glow plugs are not
damaged.
If necessary, remove glow plugs with special tool 11 6 050.Note:

Special tools 11 6 050 delivered before 4/98 should be drilled out at
9.5 mm dia. 20 mm deep.
Installation:
Tightening Torque of glow plugs,
Remove sliding rail (1) from bearing pin.Note:

The cylinder head is set up without the sliding rail (1) due to better
accessibility.
The sliding rail (1) is reinstalled at a later stage.
Remove cylinder head gasket.
Note:
If the engine is cranked with the camshafts or a cylinder head
removed, every revolution must be counted exactly so that the
TDC firing position and the overlap TDC position of the injection
pump are not confused.
Caution!
The chain wheel of the injection pump has ”no” marking for the firing
TDC position of the injection pump.
(Ratio of crankshaft to injection pump = 2:1)
Note:
If the engine has been cranked and the TDC firing position of the
injection pump is no longer known, it can be determined by way of
the adjustment value of the injection pump.
This work instruction need only be carried out if the TDC firing position of
the injection pump is no longer known.
The following describes how to look for the firing TDC position of the
injection pump.
Lift timing chain and hold under tension.

Crank engine at central bolt until piston of first cylinder is in ”TDC
position”.
The plug (1) must be released so that the static basic setting can be
measured.Installation:
Tightening Torque of plug (1),
Note:
The setting value of the injection pump is stamped next to the
nameplate.
The fuel return line (1) covers the injection pump nameplate.
Remove fuel return line (1).Installation:

Tightening torque of fuel return line (1),
Screw in special tool 13 5 200 and tighten down by hand.

Install special tool 00 2 510 (dial gauge) and secure to approx. 5 mm
preload.
Rotate engine at central bolt 90° against direction of rotation.
Set scale of dial gauge to zero.
Crank engine at central bolt in direction of rotation until piston of first

cylinder is in ”TDC position”.
Locate flywheel in TDC position with special tool 11 2 300.
Compare setting values next to nameplate and on dial gauge (tolerance
± 0.1 mm).Note:
If the pointer on the dial of the special tool 00 2 510 (dial gauge) has
not moved, the injection pump is in the overlap TDC position.
Pull special tool 11 2 300 back until flywheel is no longer secured in
position.
Crank engine at central bolt once in direction of rotation until piston is

again in TDC position.
The injection pump is now in the firing TDC position.
Note:
If necessary, check setting value of injection pump with special
tool 00 2 510 (dial gauge) again.
Installation:
Installation of cylinder head is described separately from removal. The
assembly sequence differs between removal and installation.
Clean sealing faces of cylinder head and engine block; if necessary,
remove traces of sealing compound with hardwood spatula. While
proceeding, make sure that no remnants of sealing compound drop into
the oilways and cooling ducts.
Without work on the engine block which changes the piston protrusion,
use a new cylinder head gasket with the same thickness marking
(number of holes).
If work is carried out on the crank drive or piston, the seal thickness must
be redetermined.
Measuring the piston clearance:
Place dial gauge with measuring fixture special tool 00 2 530 on the
cleaned cylinder head sealing face and set the preload to zero.
Clean piston at measuring points (1 and 2).

Place dial gauge at measuring point (1) on cleaned piston and determine
highest point by rotating crankshaft.
Measure and note down piston protrusion at measuring points (1 and 2)
on all 4 pistons.
The highest piston protrusion at the measuring points (1 and 2) of all

4 pistons determines the thickness of the cylinder head gasket.
Piston protrusion up to 0.91 mm
Install 1 hole cylinder head gasket.
Piston protrusion 0.92 ... 1.03 mm
Piston protrusion over 1.03 mm
Note:
To avoid damaging the valves when the camshafts are later
installed, it is necessary to crank the engine to 45° before TDC.
Crank engine at central bolt approx. 45° against direction of rotation.
Check that dowel sleeves are undamaged and correctly located.
Note:
The joints between timing case cover and engine block are sealed
with sealing strips that are attached as standard.
It is not necessary to apply a permanently elastic sealing
compound.
Caution!
The tapped bores in the engine block must be dirt and oil-free.
(Risk of cracks, incorrect tightening values).
Lay on new cylinder-head seal with previously determined seal thickness

(number of holes).
Fit cylinder head and tighten down using new screws (slightly oiled) in
sequence 1 ... 10.
Tightening Torque,
Use special tool 00 9 120 for torsion angle tightening.
Replace sealing ring on screw (1).

Install and tighten down screw (1) between timing case cover and
cylinder head.
Install and tighten down screws.
Note:
Shown without cylinder head for purposes of clarity.
The sliding rail (1) is guided below via a bearing pin (2).
Place sliding rail (1) from above against bearing pin (2) and press
downwards until rail (1) snaps audibly into place.
Note:
Bearing pin (1) for sliding rail has a coated thread and must be
replaced.
Install and secure new bearing pin (1) for sliding rail.
Tightening Torque,
Insert tensioning rail (2) from above.

Note:
Bearing pin (1) for tensioning rail has a coated thread and must be
replaced.
Install and secure new bearing pin (1) for tensioning rail.
Tightening Torque,
Install camshafts,
refer to 11 31 001.
Assemble engine.
11 12 100 Removing and installing cylinder head (M47TU, M47T2)

00 2 530
00 9 120
11 2 300
11 5 180
13 5 020
Important!
Fit new cylinder head bolts.
Do not wash off bolt coating.
There must be no oil or coolant in the blind holes (risk of cracking).
Protect alternator against engine oil and coolant (risk of damage).
Charge air hoses that are to be screw in place must be assembled
in a dry and grease-free state.
Charge air hoses that are plugged in (see installation note).
If the piston protrusion will not change, a cylinder head gasket with
the same strength marking (number of holes) must be used.
Remove negative lead from battery.

Remove intake plenum.
Remove injector nozzles.
Remove rail strip.
Remove cylinder head cover.
Drain coolant.
Remove EGR cooler.
Remove both camshafts.
Remove all hydraulic valve clearance compensation units and roller
cam followers.
Remove all glow elements.
Release exhaust turbochargers.
M47:
Crank engine using central bolt in direction of rotation until piston of first
cylinder is in TDC.
M47TU2:
Crank engine using central bolt in direction of rotation until piston of first
cylinder is in TDC.
Release screw (1).

The second mounting bolt is located at the end of the return line.
Release this screw as well.
Pull off locks and detach water hoses.
Pull out lock (1) and (2).

Release return pipe and water hoses.
Release screws (1).

Lift coolant branch flange.
Installation note:
Replace gasket.
Disconnect plug connection (2).
Disconnect fuel return line (3).
Disconnect plug connection (2) from temperature sensor.
Release union nuts (1) with special tool 13 5 020 .
Pull off all connectors (2).
Remove rubber mount (3).
Installation note:
Observe installation position of rubber mount.
Important!
These screws must "not" be removed.
Release screw connection (1) on gear case cover.

The screw is located on the cylinder head.
Unfasten cylinder head bolts from outside to inside in following

sequence 10 ... 1.
If work is being carried out on the crank drive or piston, the gasket
thickness must be redetermined.
Measuring the piston protrusion:
Fit dial gauge with measuring fixture special tool 00 2 530 on cleaned
cylinder head lower face and set to zero under preload.
Clean piston at measuring points (1 and 2).

Fit dial gauge at measuring point (1) on cleaned piston and determine the
highest point by turning the crankshaft.
Measure and note down piston protrusion at measuring points (1 and 2)
on all 4 pistons.
Installation note:
M47 / M57 M57TU2:
Piston protrusion 0.77 to 0.92 mm

Install 1-hole cylinder head gasket.
Piston protrusion, larger than 0.92 ... 1.03 mm
Piston protrusion, larger than 1.18 mm
Installation note:
M47TU1 / M47TU2 M57TU1 / M57TUTop:
Piston protrusion 0.72 to 0.83 mm

Check fitting sleeves (1) for damage and correct installation position.
Fit new cylinder head gasket with previously determined gasket
thickness (number of holes).
Fit cylinder head and secure with new screws (lightly oiled), tightening in
the sequence 1 ... 10.
Use special tool 00 9 120 for torsion angle adjustment.
Install and tighten down screws.
Assemble engine.
11 12 000 Removing and installing/sealing cylinder head cover (M47)
Caution!

malfunction.
E46 only:
Release expansion rivets (1).
Slide covers approx. 2 cm towards rear and lift out.
E46 and E39:

Remove air cleaner element.
Remove injection lines.
Remove injection nozzles.
Release screws and remove intake fitting.
Disconnect plug connection from air-mass flow sensor.

Detach vacuum line from vacuum reservoir.
Release retaining elements of cylinder head cover in sequence 22 ... 1.
Installation:
Clean gasket residue from sealing surfaces.
At transition to half-moon sections on inlet and exhaust sides, apply a
thin and uniform sealing bead of Drei Bond 1209, refer to BMW Parts
Service, approx. 2 mm high and 2 mm wide.
Installation:
Replace cylinder head cover gasket.
When fitting cylinder head cover, ensure gasket is correctly seated on
rear side of cylinder head.
Installation:
Screw in all retaining elements of cylinder head cover and initially tighten
without preload.
Tighten down retaining elements of cylinder head cover in
sequence 1 ... 22.
11 12 000 Removing and installing/sealing the cylinder head cover (M47TU /
M47T2)
Attention!

malfunction.
Remove the air cleaner insert.

Disconnect high-pressure lines.
Remove injectors.
Loosen the screws and remove the intake neck.

Disconnect the plug connections on the air mass meter, camshafts and
pressure sensor.
Release the affected cables.
Release the vacuum line from the vacuum reservoir.
Note:
The figures have been adopted by the M47.
Release the mounting elements of the cylinder head cover in the

order 22 ... 1.
Installation note:
Clean the seal residue from the sealing surfaces.
Apply a thin and even sealing bead (approx. 2 mm high and 2 mm wide)
with Drei Bond 1209 on the transition to the half-moon sections on the
intake and exhaust side, see BMW parts service.
Installation note:
Renew the gasket of the cylinder head cover.
When mounting the cylinder head cover, ensure that the gasket is
correctly fitted on the rear face of cylinder head.
Installation note:
Screw in all the mounting elements of the cylinder head cover and apply
without preload.
Tighten the mounting elements of the cylinder head cover in the
order 1 ... 22.
11 12 101 Replacing cylinder head gasket (M41 / M47)
Work identical to removing and installing cylinder head,

refer to 11 12 100.
11 12 501 Replacing cylinder head gasket (M47 /M47TU)
(engine removed)
Scope of work is identical to

11 12 101 Replacing cylinder head gasket (M57 /M47TU)
Tasks are identical to

11 13 500 Removing and installing, sealing / replacing oil sump (M47)
(engine removed)
Secure engine to assembly frame.

This work is described in the work step Removing and installing cylinder
head,
refer to 11 12 500.
Drain engine oil,
refer to 00 00 249.
Unfasten oil pan screws on transmission end.
Unfasten oil pan screws and lift off oil pan.
Installation:
Sealing faces clean and free of seal debris.
Check gasket, replace if necessary.
Apply Drei Bond 1209 sealing compound to area around joint (refer
to BMW Parts Service): approx. 3 mm wide and 2 mm high.
Installation:
To prevent any possibility of torsion stress during subsequent
transmission assembly, align oil pan flush with side of transmission.
11 13 000 Removing and installing, sealing or replacing oil sump (M47)

00 0 200
00 0 201
00 0 202
00 0 204
00 0 208
00 2 030
31 2 220
Note:
To remove oil sump:
lower front axle support.
There is no need to perform a front axle alignment check.
Remove engine underguard.
Caution!
When working on oil, coolant or fuel circuit:
protect alternator against contamination.

malfunction.
Drain engine oil.
E46 only:
Remove microfilter.
Open cable duct on lower section of microfilter housing (2) and feed out
cable(s).
Release screws (1) and remove lower section of microfilter housing (2).
Note:
Screw (1) is not visible.
Release screws.
Remove acoustic cover at front.
Remove intake snorkel.
Unclip hoses, remove hose holder (1).
Detach rubber strip (1).

Release locks (2) and remove side trim panel.
E39 only:
Release screws.
Withdraw snorkel (1) from corrugated tube (2) and remove.
Release screws.
Remove acoustic cover (1).
E46 and E39:

Assemble special tool 00 0 200 with special tool 00 0 201 / 00 0 202
/ 00 0 204 / 00 0 208 and install.
Secure special tool 00 0 200 to front engine suspension eye.
Note:
The supports (1) of special tool 00 0 208 must rest on the bolt
connection of both side walls.
Tighten down screws (1 and 2).

Raise engine approx. 5 mm with special tool 00 0 200 .
Release screws.
Remove acoustic cover on left.
Installation:
Check rubber grommet for guiding left acoustic cover in oil filter housing,
replace if necessary.
Insert guide pins of left acoustic cover:
into rubber grommet on oil filter housing
into bore of acoustic cover at rear
Release guide tube for oil dipstick.

Installation:
Replace O-ring.
Remove clamping screw on steering spindle.

This operation is described in the work step "Removing and installing
steering gear."
Installation:
Detach left and right stabilizers on engine carrier.

Installation:
Installation regulations and tightening torque, 31 35 000.
Support front axle support with special tool 00 2 030 in conjunction with
special tool 31 2 220 .
Remove front end reinforcement. Release right and left engine mounts at
bottom. Release left and right control arms on engine carrier. Release
screw connection for front axle support and lower front axle support.
These operations are described in the work step "Replacing front axle
support".
Note:
There is no need to detach the steering gear from the front axle support.
Detach cable for oil level sensor and reverse gear (E46 only) from oil
sump.
Disconnect plug connection to oil level sensor.
Release oil sump screws on transmission side.
Release screws and remove oil sump towards rear.
Installation:
Clean sealing surface to remove all gasket remnants.
Apply approx. 3 mm wide, 2 mm high coat of Drei Bond 1209 sealing
agent (refer to BMW Parts Service) to the area around seams.
Replace seal.
Installation:
Install all oil sump screws.
Initially tighten oil sump screws on transmission side still without
preload.
Tighten down oil sump screws on engine side.
Tighten down oil sump screws on transmission side.
11 13 000 Removing and installing, sealing or replacing oil sump (M47TU)

00 0 200
00 0 201
00 0 202
00 0 204
00 0 208
Note:
To remove oil sump:
Lower front axle support.
There is no need to perform a front axle alignment check.
Unscrew and remove splash guard.
Important!

malfunction.
Drain engine oil.
Remove microfilter.
cable(s).
Release screws (1).
Remove lower section of microfilter housing (2).
Remove expansion rivets.
Release intake hood in direction of arrow and remove in opposite
direction together with intake snorkel.
Release screws.
Lift off acoustic cover.
Remove heater bulkhead.
Release screws.
Remove rear acoustic cover.
Remove lower section of microfilter housing.
Assemble special tools 00 0 200 with special tools 00 0 201 / 00 0 202

/ 00 0 204 / 00 0 208 and attach.
Note:
Release oil dipstick guide tube on manifold.Installation:

Replace O-ring.
Note:
Lower front axle support.
Detach cable for oil level sensor from oil sump.

Disconnect plug connection to oil level sensor.
On car with automatic transmissions, detach retaining fixture of oil lines to
heat exchanger.
Release oil sump screws on transmission side.
Release remaining screws and remove oil sump towards rear.
Clean sealing surface to remove all gasket remnants.
Installation:
Use liquid gasket 2.1.
Apply a thin and uniform layer of liquid gasket in area (1)

at end cover to engine block.
Important!
Oil sump gasket must not be lubricated.
Install oil sump with a new gasket.
Installation:
Install all oil sump screws.
Initially tighten oil sump screws on transmission side still without
preload.
Tighten down oil sump screws on engine side.
Tighten down oil sump screws on transmission side.
11 14 110 Removing and installing, sealing/replacing timing case cover at
bottom (M47)
Caution!

malfunction.
Remove oil sump,

refer to 11 13 000.
Note:
After removing oil sump, reinstall front axle carrier provisionally and
remove special tool 00 0 200.
Remove cylinder head,

refer to 11 12 100.
Remove vibration damper,

refer to 11 23 010.
Remove radial seal,
refer to 11 14 141.
Note:
Install new radial seal only after installing timing case cover.
Remove vane pump belt pulley, remove vane pump from timing case
cover (lines remain connected),
refer to 32 41 060.
Remove alternator drive belt tensioner,
refer to 11 28 020.
Remove water pump,
refer to 11 51 000.
Remove alternator,
refer to 12 31 020.
If necessary, unfasten bearing pin on timing case cover with special tool
11 2 360.Installation:
Tightening Torque,
Unfasten screws and remove timing case cover.
Installation:
Check adapter sleeves (1) for damage and correct installation
position.
Installation:
Seals for timing case cover and oil pump can only be obtained as a
paired set.
When carrying out repairs on timing case cover, cut seal at marked
points.
Installation:
Replace seal.
Apply a thin coat of Drei Bond 1209 sealing compound (refer to
BMW Parts Service) to front and rear ends of seal.
Install timing case cover, insert all screws and initially tighten to approx.
5 Nm.
Firmly tighten all screws in alternate sequence.
Note:
M7 screws.
Tightening Torque,
Caution!
If all screws are tightened, they must be tightened again in a second
operation.
Replace radial seal,

refer to 11 14 141.
Assemble engine.
11 14 110 Removing and installing, sealing/replacing timing case cover at
bottom (M47TU / M47T2)

00 0 200
11 3 340
Important!

malfunction.
Remove oil sump.

Note:
After removing oil sump, reinstall front axle support provisionally and
remove special tool 00 0 200 .
Remove cylinder head.
Remove vibration damper.

Remove radial seal.
Note:
Install new radial seal only after installing timing case cover.
Remove pulley for vane pump.

Remove vane pump from timing case cover. (Lines remain connected).
Remove alternator drive belt tensioner.
Remove water pump.
Remove alternator.
Unfasten screws and remove timing case cover.
Lock lower hydraulic chain tensioner with special tool 11 3 340 (alignment
pin).
Detach clamping rail (3).
Detach guide rail (4).
Release screw connection of sprocket wheel for H.P. pump (2).
Installation:
Tightening torque 13 52 2AZ
Remove sprocket wheels with chain.

Installation:
Check dowel sleeves (arrow) for damage and correct installation
position.
Installation:
Gasket is only available for timing case cover and water pump
together.
When repairing timing-chain cover, detach seal at marked points.
Installation:
Replace gasket.
Apply a thin coat of Drei Bond 1209 sealing agent (refer
to BMW Parts Service) to gasket at ends (arrow) on both sides.
Fit timing-chain cover.

Insert all screws and initially tighten to approx. 5 Nm.
Fully tighten all screws in alternate sequence.
Note:
M7 screws.
Important!
Once all screws have been tightened down, retighten them in a
second operation.
Replace radial sealing ring.
Assemble engine.
11 14 151 Replacing crankshaft radial seal (M47 / M57)

00 5 500
11 1 260
11 2 213
(transmission side)
Remove transmission.
Drain engine oil.
Remove flywheel.
Unfasten oil pan screws on transmission end.

Loosen oil pan.
Release screws in end cover at rear.

Carefully detach oil sump gasket from end cover, remove end cover.
Note:
Check sump gasket for damage after removing end cover.
If necessary, remove oil sump and replace oil sump gasket.
Note:
As from 4/98, a new type of radial seal is used in the Series and as a
replacement. This radial seal may only be supported with a ”support
bushing”.
If the radial seal is stored for more than six months without the
support bushing (1), its operational reliability will no longer be
guaranteed.
The radial seal must not be reused.
Distinguishing feature:
(1) New version ”without hose spring”
(2) Old version ”with hose spring”
Caution!
The sealing lip of the new version (1) is very sensitive and must not
be kinked under any circumstances. Do not touch the sealing lip with
your fingers.
Note:
The end cover is offered in the kit with a radial seal.
If necessary, lift out the radial sealing ring and drive in new sealing ring
using special tool 11 1 260 in conjunction with special tool 00 5 500 .
Make sure dowel sleeves (1) are correctly seated.

Replace seal (2).
Apply thin, uniform coat of Drei Bond 1209 sealing compound (refer to
BMW Parts Service) to edges of joint on oil pan.
Caution!
Do not use special tool 11 2 213 for the new radial seal version.
Note:
When fitting the end cover with radial seal on the crankshaft, it is
only permitted to use the ”support bushing (1) as an installation
tool.
Lubricate contact face of crankshaft.

Caution!
Push on end cover with support bushing (1) straight and without
tilting sideways.
Insert all screws and tighten down end cover.
Note:
Store the support bushing (1) of the new radial seal version as a
”special tool”, then render special tool 11 2 213 unusable and
dispose of.
The old and new radial seal versions can be installed with the
support bushing (1).
11 14 151 Replacing crankshaft radial seal (M47TU / M47TU2)
(Transmission side)
Drain engine oil.
Remove flywheel.
Unfasten oil sump screws on transmission end.

Loosen oil pan.
Release screws in end cover at rear.

Carefully detach oil sump gasket from end cover, remove end cover.
Note:
Check sump gasket for damage after removing end cover.
If necessary, remove oil sump and replace oil sump gasket.
Note:
The end cover is supplied in the set with a built-in radial seal and a
support bushing. The support bushing is fitted on the radial seal (to
provide protection during transportation and storage).
Note:
When fitting the end cover with radial seal on the crankshaft, it is
only permitted to use the ”support bushing (1)” as an installation
tool.
Lubricate contact face of crankshaft.

Important!
Push on end cover with support bushing (1) straight and without
tilting sideways.
Insert all screws and tighten down end cover.

Note:
Store support bushing (1) of new radial seal version as a ”special
tool”.
The old and new radial seal versions can be installed with the
support bushing (1).
Make sure dowel sleeves (1) are correctly seated.Note:

Illustration shows connected segment gear.
11 14 141 Replacing radial seal in lower timing case cover (M47)
Remove vibration damper,

refer to 11 23 010.
Fit special tool 11 2 383 to crankshaft.
Removing radial sealing ring:

Screw in special tool 11 6 360 until it has made firm contact with radial
seal.
Then remove radial seal by turning screw.
Installation:
Lubricate sealing lip of new radial seal and slide over special
tool 11 6 340 until radial seal contacts timing case cover.
Remove special tool 11 6 340.
Installation:
Insert central screw.
Using special tool 11 6 350 and central screw, install radial seal flush
with timing case cover.
11 14 141 Replacing radial seal in timing case cover at bottom (M47TU /
M47TU2)

11 1 210
11 1 212
11 5 110
11 7 400
11 7 410

Remove vibration damper.
Removing radial sealing ring:

Screw in special tool 11 1 210 until it is firmly connected to radial seal.
Then remove radial sealing ring by turning screw.
Installation:
Oil sealing lip of new radial seal and push over special tool 11 7 400
until radial seal rests against timing case cover.
Remove special tool 11 7 400 .
Installation:
Insert central screw.
Using special tool 11 5 110 and central bolt 11 7 410 , install radial
seal flush with timing case cover.
Assemble engine.
11 21 531 Replacing all crankshaft main bearing shells (M47/M47TU)

00 2 590
00 9 120
11 2 110
(engine dismantled)
Important!
Check grinding stage of crankshaft.
Installation note:
When replacing bearing shells (also for replacement crankshafts),
classification does not apply for allocation of bearing shells in
crankcase.
Only fit yellow bearing shells into the crankcase.
Note:
The axial guidance on the crankshaft is fitted to bearing position 4.
Insert the guide bearing shell in the engine block.
The crankshaft is marked with yellow, green or white paint, depending on
the tolerance of the main bearing journal.
Installation note:
The bearing shell classification for the bearing cap is marked on the
crankshaft in yellow, green or white paint.
The bearing shells are marked with yellow, green or white paint.
1. Bearing shell
2. Guide bearing
Observe grinding stage of main bearing journals.
Note:
Main bearing caps 1 .... 5 are marked on exhaust side.
Check the main bearing clearance on the crankshaft.
Install crankshaft. Fit special tool 00 2 590 (Plastigage type PG1) to oil-
free crankshaft.
Do not twist crankshaft.
Install main bearing cap so that grooves in main bearing shell guide are
on one side.
Align main bearing cap flush with side of bearing seat.
Note:
To check main bearing clearance, use the used main bearing
screws.
There must be no oil in the blind holes (risk of cracking).
Wash and oil main bearing screws.
Tightening specifications for main bearing:

1. Tighten screws to jointing torque.
2. Tighten down bolts with special tool 11 2 110 or with special tool
00 9 120 to angle of rotation.
Remove main bearing cap. Read off bearing clearance at width of
crushed plastic thread (Plastigage) with aid of measuring scale.
If necessary, to correct bearing clearance, fit new bearing shells, or ones
with a different colour coding.
Overview:
Colour code/shaft diameter/bearing strength
Ge = yellow
Gn = green
Ws = white
1. Crankshaft
2. Bearing clearance
3. Bearing shells: Yellow, green, white
4. Bearing cap
Note:
Remove plastic thread.
Coat main bearing shells and crankshaft with engine oil.
Install main bearing cap so that grooves in main bearing shell guide are
on one side.
Align main bearing cap flush with side of bearing seat.
Note:
Always replace main bearing screws with new ones.
There must be no oil in the blind holes (risk of cracking).
Wash and oil main bearing screws.

1. Tighten all screws on main bearing cap with jointing torque.
2. Loosen the screws on the main bearing cap 4.
3. Strike back and front of crankshaft with plastic hammer to centre
guide bearing (do not damage crankshaft).
4. Tighten bolts of main bearing cap no. 4 to jointing torque.
5. Tighten all screws of the main bearing cap using special
tool 11 2 110 or special tool 00 9 120 to the angle of rotation.
Check side clearance.
If necessary, check guide bearing shells, crankshaft and engine block.
11 21 500 Replacing crankshaft (M47 / M47TU)

00 9 120
11 2 110
(engine removed)
Remove oil pump.

Remove end cover at rear.
Remove all pistons.
If permitted axial clearance is exceeded, check crankshaft and guide

bearing shells, replace if necessary.
Axial clearance.
Unfasten screw connection on main bearing.

Remove main bearing cover 1...5.
Lever out crankshaft.
Note:
Bearing caps 1...5 are marked on exhaust side.
Bearing cap 4 is on the crankshaft thrust bearing.
Replace main crankshaft bearing shells.
Installation:
Coat bearing shells with oil.
Install crankshaft.
Fit bearing caps 1...5 (bearing 1 on drive side of camshaft) so that
grooves of bearing shell guide lie on one side.
Align bearing cap precisely.
Installation:
Screws of main bearing caps must always be replaced with new
screws.
No oil is permitted in the blind bores!
(risk of cracking).
Screws washed and oiled.

1. Tighten all screws on main bearing cover with jointing torque.
2. Unfasten screws in main bearing cover 4.
3. Strike back and front of crankshaft with plastic hammer to center
guide bearing (do not damage crankshaft).
4. Tighten screw on main bearing cover 4 to jointing torque.
5. Tighten down all screws of main bearing caps with special
tool 11 2 110 or with special tool 00 9 120 to torsion angle.
Check axial play.

Replace conrod bearing shells.
Replace grooved ball bearings in crankshaft.
11 21 571 Replacing deep-groove ball bearing in crankshaft (M47 / M47TU /
M57)

00 5 500
11 2 340
11 2 350
(clutch removed)
Remove guide bearing with special tool 11 2 340 .
Install new guide bearing.

Drive in bearing with special tool 11 2 350 in conjunction with special tool
00 5 500 as far as it will go.
11 22 500 Removing and installing or replacing flywheel (M47 / M47TU)

11 2 170
(clutch removed)
Block flywheel with special tool 11 2 170 .
Unfasten screws and remove flywheel.
Installation:
Check dowel sleeve for damage and correct installation position.
Note:
Position of dowel sleeve (1) in dual-mass flywheel is identified by
two notches next to associated bolt hole.
Installation:
Clean thread and install new micro-encapsulated screws.
11 22 513 Replacing roller bearing for dual-mass flywheel

21 2 051
21 2 052
Note:
Flywheel removed!
Using hydraulic press (1) and special tool 21 2 051 , press out dual-mass
flywheel downwards on engine side.Important!
Risk of damage:
Roller bearing must not be driven out.
Push roller bearing (2) onto special tool 21 2 052 .

Using hydraulic press (1), press roller bearing into dual-mass flywheel as
far as it will go on clutch side.
Important!
Risk of damage:
Observe press-in instruction:
Roller bearing must not be driven in.
Roller bearing mounting force/travel monitored:
Min. 2000N 1 mm before end of pressing in.
Max. 15000N during entire press-in procedure.

00 5 500
11 2 010
11 2 343
11 2 350
Note:
Flywheel removed!
Position special tool 11 2 010 in roller bearing.

Twist out roller bearing with special tool 11 2 343 .
Assemble special tools 11 2 350 and 00 5 500 .

Drive in roller bearing with special tools 11 2 350 and 00 5 500 in direction
of arrow as far as it will go.
Assemble engine.
11 23 010 Removing and installing or replacing vibration damper (M47)

refer to 11 28 010.
Position special tool 11 6 310 on vibration damper.

Protect engine bracket from damage.
Insert wood between engine support and special tool 11 6 310.
Release central bolt, remove vibration damper.
Note:
The vibration damper is located in the crankshaft with a parallel key.
Caution!
Danger of incorrect assembly.
Align opening in vibration damper to parallel key.
Insert central bolt when parallel key is noticeably located between
opening.
Installation:
Mount vibration damper and align opening to parallel key.
Install new central bolt.
Position special tool 11 6 310 on vibration damper.
Protect engine bracket from damage.
Insert wood between engine support and special tool 11 6 310.
Tighten down central bolt.
Tightening torque,
11 23 010 Removing and installing or replacing vibration damper (M47TU /
M47TU2)

00 9 140
11 8 010
11 8 182
11 8 183
11 8 185
11 9 260
11 9 265
Important!
A changed vibration damper is installed on vehicles from model year
3/2003.
Use tool with 3/4-inch powertrain to release central bolt.
On vehicles with 5 gears (F transmission) there is no recess on
transmission, and it must be removed to secure the crankshaft.

Remove reinforcement plate.
Remove fan cowl with radiator shutter.
Remove A/C compressor drive belt.
Remove the alternator drive belt.
Remove power steering pump drive belt.
Release exhaust system brackets on transmission.
Note:
Vehicles with H transmission with aperture.
Secure special tool 11 8 182 / 11 8 183 and 11 8 185 with supplied

screws (1).Installation note:
Adjust special tool 11 8 185 with the adjusting sleeve.
E83 Only:
Remount special tool 11 8 183 (see graphic).
Secure special tool 11 8 183 with Torx screws (1).
Secure special tool 11 8 182 in flywheel.
Secure screw connections on special tool 11 8 183 .
Note:
Transmission removed.
Secure flywheel with Torx screw (1), special tool 11 9 260 / 11 9 265 .
Note:
Vehicles with automatic transmission (GM-5).
Release exhaust holder from transmission.

Slide in special tool 11 8 010 into transmission opening (see graphic).
Lie special tool flat in direction of arrow on transmission housing.
Note:
Vehicles with automatic transmission (6HP-19).
Secure special tool 11 8 183 with Torx screws (1).

Secure special tool 11 8 182 in flywheel (2).
Secure screw connections on special tool 11 8 183 .
Release central bolt with reinforced socket (2) with 3/4-inch
powertrain (1).
Secure central bolt with special tool 00 9 140 .

Stick special tool 00 9 140 with magnet (1) on engine.
Installation note:
A 3/4-inch powertrain (2 and 3) is required for securing central bolt.
Assemble engine.
11 24 571 Replacing all conrod bearings (M47 / M47TU)

00 2 590
00 9 120
11 2 110
(piston removed)
Install new conrod bearing shells.Note:

The conrod bearing shells for the conrod and the conrod cover are
different.
Install the normal conrod bearing shell in the conrod cover (low version).
Install wear-resistant ”S” conrod bearing shell (high version) in conrod.
For each conrod, install red and blue bearing shell (irrespective of color
coding on conrod shaft).Caution!
Note grinding stages on crankshaft.
Install piston.
Check connecting-rod bearing clearance:

Piston in BDC position.
Place special tool 00 2 590 (Plastigage model PG 1) on oil-free
crankshaft.
Fit bearing caps so that pair numbers match up.
Caution!
Do not turn the connecting rods or crankshaft.
Use conrod bolts to check conrod bearing clearance.

Tighten down conrod bolts with special tool 00 9 120 or special
tool 11 2 110
Remove bearing cap. Read off bearing clearance at width of crushed

plastic thread with aid of measuring scale.
Conrod bearing clearance.
Remove plastic thread.
Summary:
Color code / shaft diameter / bearing strength
rt = red
bl = blue
1. Crankpin
2. Bearing clearance
3. Bearing shells: red or blue
4. Conrod
11 25 530 Removing and installing or replacing all pistons (M47)
(engine removed)
Remove cylinder head,
refer to 11 12 500.
Remove oil sump,
refer to 11 13 500.
Removal:
Removal of all pistons is described separately from installation. The
assembly sequence for removal and installation is different.
Remove intake neck of oil pump.
Remove reinforcement shell.
Note:
Before removing pistons, remove carbon deposits from cylinder
walls.
Remove connecting-rod cover.
Remove connecting rods with pistons from cylinder head end.
Lift out retaining ring and press out piston pin.Caution!

Piston and piston bolts are paired and must not be fitted individually.
Installation:
Installation of all pistons is described separately from removal. The
Before installation, measure piston installation clearance. Measure

piston diameter with micrometer at measuring point A from bottom edge
of piston and offset at 90° to the axis of the piston pin.
Distance A,
refer to Technical Data.
Adjust micrometer on cylinder bore of engine block and set plug gauge
on micrometer to zero. Measure bottom, center and top of cylinder bore
in direction of travel and direction of engine rotation.
Diameter of cylinder bore,
Piston installation clearance,
Permissible total wear clearance,
If necessary, replace connecting rods.
The BMW Parts Service only supplies connecting rods in complete sets.
Note:
It should be possible to press piston pin into bush by hand using
only slight pressure. Clearance should then be minimal.
Replace conrod bearing shells,

refer to 11 24 571.
Fit the connecting rod to the piston in such a way that, when the pair
number is visible, the installation arrow on the piston points to the right.
Caution!
Fit the retaining ring with its aperture opposite to recess.
Caution!
Re-install piston, connecting rod and bearing shells back in the
same position and in the same installation location.
Connecting rods and bearing covers are designated with the same
pair number: do not mix them.
Insert special tool 11 6 330 in conrod.
Lightly coat pistons and piston rings with oil.

Align contact points on piston rings (offset at approx. 120°, but do not
arrange over piston pin lug).
Press together piston rings with special tool 11 2 260.
Install pistons with arrows pointing towards camshaft drive.

The entire circumference of the tightening strap must be flush with the
crankcase.
Caution!
Danger of piston ring failure.
Only press pistons into place with finger force - do not knock in!
Attach crankpin to connecting rod.

Apply light coat of oil to connecting-rod bearing shells.
Place bearing caps in position, making sure that matching numbers are
paired.
Install new connecting-rod screws.
Tighten down conrod screws with special tool 00 9 120 or special

tool 11 2 110.
Tightening torque,
Note:
Fit reinforcement shell in correct installation direction.
Arrows point forwards.
Install and secure reinforcement shell.
Clean sealing surface, replace seal between intake neck and oil pump.
Install and secure intake neck of oil pump.
Assemble engine.
11 25 530 Removing and installing or replacing all pistons (M47TU / M47T2)

00 9 120
11 2 110
11 2 260
11 6 330
(engine removed)
Remove oil sump.
Removal:
Removal of all pistons is described separately from installation. The
Remove mass balance/oil pump.Installation:

Tighten screws according to numbering sequence.
Note:
Before removing pistons, remove carbon deposits from cylinder
walls.
Unscrew conrod bearing cover.

Remove connecting rods with pistons from cylinder head end.
Lift out retaining ring and press out piston pin.Important!
Installation:
Installation of all pistons is described separately from removal. Assembly
sequence for removal and installation is different.
Before installation, measure piston installation clearance. Measure

piston diameter with micrometer at measuring point A from bottom edge
of piston and offset at 90° to the axis of the piston pin.
Distance A.
Adjust micrometer to cylinder bore of engine block.

Set internal caliper on micrometer to zero.
Measure cylinder bore at bottom, in middle and at top in direction of travel
and also vertically in each case.
Diameter of cylinder bore.
Piston installation clearance.
Total permissible wear tolerance.
If necessary, replace connecting rods.

The BMW Parts Service only supplies connecting rods in complete sets.
Note:
The piston pin must be able to be pressed through the liner by hand
with little force and must not display any significant play.
Replace conrod bearing shells.
Fit conrod to piston in such a way that both of the visible pair numbers on
the installation direction arrow on the piston point to the right.
Important!
Install snap ring so that opening is opposite recess.
Important!
Re-install piston, conrod and bearing shells back in the same
position and in the same installation location.
Connecting rods and bearing covers are designated with the same
pair number: do not mix them.
Insert special tool 11 6 330 in conrod.

Lightly coat pistons and piston rings with oil.
Align contact points on piston rings (offset at approx. 120°, but do not
arrange over piston pin lug).
Press together piston rings with special tool 11 2 260 .
Install piston so that arrow points to camshaft drive.

Entire circumference of tightening strap must rest firmly on crankcase.
Important!
Danger of piston ring failure.
Press in piston only with finger force (do not knock in!).
Attach crankpin to connecting rod.
Apply light coat of oil to connecting-rod bearing shells.

Fit bearing caps so that pair numbers match up.
Install new conrod bolts.
Tighten down conrod bolts with special tool 00 9 120 or special
tool 11 2 110 .
Tightening torque, 11 24 1AZ
Clean sealing surface.
Assemble engine.
11 25 671 Replacing piston rings on all pistons (M47 / M47TU)
(piston removed)
Remove piston rings with a piston-ring compressing pliers.Note:

It might not be possible to find the identification on used piston
rings.
Put aside piston rings in correct sequence and installation position.
Installation:
Install piston rings with ”TOP” to piston top.
1. Twin-sided keystone
2. Taper face compression ring
3. Beveled roof ring with rubber-lined spring
Offset the contact points of the piston rings by approx. 120° to each
other but do not position above the piston pin boss.
Measure axial play.

Axial clearance.
Measure end clearance.

End clearance.
11 27 110 Removing and installing/replacing balancing shaft housing and
balancing shafts
Note:
Operation is described in:
Removing and installing oil pump.
11 28 060 Removing and installing A/C compressor belt tensioner (M57 /
M47TU)
Note:
If the drive belt is to be reused, mark direction of travel and reinstall
drive belt in same direction of rotation.
Remove and install fan cowl.
Remove front splash guard.
Press belt tensioner back at hexagon head (1).

Remove drive belt (2).
Installation:
Check drive belt for coolant and oil residue and replace if
necessary.
Caution!
The drive belt must be replaced if it is contaminated with hydraulic
fluid.
Fit drive belt and check if it is correctly located on pulleys.
Loosen screws (1).

Release screw on belt tensioner (3) at rear.
Withdraw tensioning roller with lever (2) in direction of arrow.
Remove belt tensioner (3).
Installation:
Opening on housing of belt tensioner must point downwards.
Align belt tensioner.
Insert screws but do not tighten down yet. Install tensioning roller
with lever and then tighten down screws.
11 28 020 Removing and installing alternator drive belt (M57 / M47TU)
Remove and install A/C compressor drive belt

Remove and install alternator drive belt
Note:
For M57 engine.
Loosen screws (1).

Remove air duct (2).
Release screw (1).

Remove roller (2).
Release screw (1).

Slacken screw (2) only.
Tilt alternator to one side.
Release self-locking nut (1).Installation:

Replace self-locking nut.
Withdraw tensioning roller with lever (1) in direction of arrow.
Loosen screws (1).

Remove belt tensioner (2).
Installation:
Opening on housing of belt tensioner (2) must be turned to
alternator.
Align belt tensioner, insert screws (1) but do not tighten down.
Install tensioning roller with lever and then tighten down screws (1).
11 28 010 Removing and installing/replacing alternator drive belt (M57 /
M47TU)
Note: If the drive belt is to be reused, mark direction of travel and

reinstall drive belt in same direction of rotation.
Loosen screws (1).

Remove acoustic cover (2) at front.
Note:
For M47TU engine.
Release screws.
Remove fan cowl.

Remove and install A/C compressor drive belt.
Caution!
Belt tensioner is under spring pressure.
Position tool vertically and pointing upwards on hexagon head.

Press belt tensioner (1) back in direction of arrow.
Remove drive belt.
necessary.Caution!
fluid.
Arrangement of drive belt (1 and 2).Caution!
Check correct position of drive belt (1 and 2) in grooves of drive
gears.
Note:
Illustration similar.
11 28 050 Removing and installing/replacing drive belt (elastobelt) for A/C
compressor (M47TU / M47T2)

11 0 331
11 0 332

If necessary, release bracket on A/C compressor.
Crank engine in direction of engine rotation.

At the same time, pull off drive belt (2) towards front in direction of arrow
using a clean cloth (1).
Remove drive belt (1) towards front.
While turning, push special tool (2) 11 0 332 onto special tool (1)
11 0 331 .
Fit drive belt (1) on A/C compressor.

Pull drive belt (1) with special tools 11 0 331 and 11 0 332 onto belt pulley
in direction of arrow.
Installation:
Check installation position of drive belt.
Assemble engine.
11 28 050 Replacing A/C compressor drive belt (M57 / M47TU)
Press belt tensioner back at hexagon head (1).

Remove drive belt (2).
Installation:
necessary.
Caution!
fluid.
11 28 010 Replacing alternator drive belt (M47)

11 3 340
Note: If the drive belt is then reused:

Mark direction of travel
Reinstall drive belt in same direction of travel
E46 with manual transmission only:

Remove radiator blind.
E46 with automatic transmission and E39:
Remove fan cowl.
If necessary, remove A/C compressor drive belt.
Caution!
Risk of drive belt tensioner breaking. Do not use a screwdriver.
Position external square drive of a 1/2 inch socket extension in opening

in drive belt tensioner.
Caution!
Carefully and slowly pretension drive belt tensioner with 1/2 inch socket
extension and lock with special tool 11 3 340 .
Remove drive belt.
Check drive belt for coolant and oil residue, replace if

necessary.Caution!
If contaminated with hydraulic fluid:
replace drive belt without fail.
Install drive belt as pictured.Caution!
Check correct position of drive belt in grooves of drive gears.
11 28 020 Replacing alternator drive belt tensioner (M47)

refer to 11 28 010.
Caution!
Carefully and slowly pretension belt tensioner with a 1/2" socket wrench
extension and remove special tool 11 3 340.
Release plug (1) and seal plug (2 and 3), remove belt
tensioner.Installation:
Replace O-ring on plug (1).
Tightening Torque of plug (1),
Note:
The hydraulic belt tensioner is filled with oil, so that a removed
element must always be stored standing upright.
Incorrectly stored elements can usually be vented by pressing into
installed position several times.
11 28 050 Replacing compressor drive belt for air conditioning (M47)
Note:
If the drive belt is to be reused, mark direction of travel and reinstall
drive belt in same direction of rotation.
Remove engine splash guard.
Push back belt tensioner at hexagon head and remove drive belt.
Installation:
necessary.
Caution!
It is essential to replace drive belt if it comes into contact with
hydraulic fluid.
11 31 505 Adjusting camshaft timing (M47)
(refer to Oper. No. 11 31 005)
Note:
Before carrying out adjustments, it is essential to check the
camshaft timing again,
refer to 11 31 005.
Remove vacuum pump,

refer to 11 66 000.
Note:
When releasing camshaft screw connection, grip camshafts at
hexagon drive.
Slacken screw (1).

Slacken screw (2).
Note:
Tighten screws (1 and 2) so that they are free of play, chain wheels
can still be turned to camshaft.
Fit special tool 11 6 322 from special tool kit 11 6 320.

Align inlet camshaft.
Note:
Special tool 11 6 320 must lie flush on cylinder head.
Locate inlet camshaft with special tool 11 6 320.
Note:
When tightening camshaft screw connection, grip camshaft at
hexagon drive.
Tighten down inlet chain wheel with special tool 00 9 120.

Tightening Torque,
Align exhaust camshaft.

Note:
Locate exhaust camshaft with special tool 11 6 320.

Note:
When tightening camshaft screw connection, grip camshaft at
hexagon drive.
Tighten down exhaust chain wheel with special tool 00 9 120.

Tightening Torque,
Remove special tool 11 6 320 from exhaust camshaft.
Pull back special tool 11 2 300 until flywheel is no longer located in

position.
Crank engine at central bolt twice in direction of rotation until first cylinder
is in firing TDC position again.
Crank engine in direction of rotation up to TDC position.

Caution!
Secure crankshaft in TDC position with special tool 11 2 300.
Fit special tool 11 6 320 to inlet camshaft.Note:

Fit special tool 11 6 320 to exhaust camshaft.Note:


Install plug in alignment bore.
Assemble engine.
11 31 505 Adjusting camshaft timing (M47TU)

00 9 120
11 2 300
11 6 320
11 6 322
(for task number 11 31 005)
Note:
Before carrying out the adjustment work, you must check the
camshaft timing.
Remove vacuum pump.
Note:
When releasing camshaft screw connections, grip camshafts at
hexagon head (2).
Slacken screw (6).

Slacken screw (3).
Note:
Initially tighten screws (6 and 3) without play.
Sprocket wheels remain rotatable with respect to camshaft.
Fit special tool 11 6 322 from special tool kit 11 6 320 .
Align inlet camshaft.
Note:
Special tool 11 6 320 must rest without a gap on cylinder head.
Secure inlet camshaft with special tool 11 6 320 .
Note:
When tightening down camshaft screw connection, grip inlet
camshaft at hexagon head (2).
Tighten down sprocket and gear wheels with special tool 00 9 120 .
Align exhaust camshaft.

Note:
Secure exhaust camshaft with special tool 11 6 320 .

Note:
When tightening down camshaft screw connection, grip exhaust
camshaft at hexagon head.
Tighten down exhaust-side gear wheel with special tool 00 9 120 .


position.
is nearly in firing TDC position again.
Caution!
Do not crank engine back.
Secure crankshaft in TDC position with special tool 11 2 300 .
Place special tool 11 6 320 without holder also illustrated on inlet

camshaft.Note:
Place special tool 11 6 320 without holder also illustrated on exhaust

camshaft.Note:

Install plug in special tool bore.
Assemble engine.
11 31 005 Checking camshaft timing (M47)
Remove cylinder head cover,

refer to 11 12 000.
Crank engine at central bolt in direction of rotation until first cylinder is in

firing TDC position.
Remove plug from alignment bore.

Hold crankshaft in TDC position with special tool 11 2 300.
Caution!
Remove special tool 11 2 300 before switching on the engine.

Fit special tool 11 6 320 to exhaust camshaft.

Note:
If necessary, adjust camshaft timing,

refer to 11 31 505.
11 31 005 Checking camshaft timing (M47TU)

11 2 300
11 6 320

Camshafts (1) are situated in position shown in illustration.
Remove plug from special tool bore.

Hold crankshaft in TDC position with special tool 11 2 300 .
Caution!
Remove special tool 11 2 300 before switching on the engine.
Place special tool 11 6 320 on inlet camshaft.Note:

Place special tool 11 6 320 on exhaust camshaft.
Note:
If necessary, adjust camshaft timing.

11 31 091 Removing and installing/replacing hydraulic chain tensioner (M47)
Remove timing case cover at bottom,

refer to 11 14 110.
Press in clamping piston at bottom and lock with special tool 11 3 340
(alignment pin).
Unscrew and remove chain tensioner.
Warning!
Tensioner pistons are under spring pressure.
When plug pins are removed, there is a risk of injury.

11 31 091 Removing and installing/replacing hydraulic chain tensioner
(M47TU / M47T2)

11 3 340
Remove front timing case cover.
Press both tensioner rails (1) in direction of arrow. Insert special tool
11 3 340 in designated openings in chain tensioner (3).
Release screws (3).
Remove chain tensioner (2).
Note:
The illustration shows the upper tensioner rail already removed and the
chain tensioner secured with the special tool.
Warning!
Risk of injury during removal of plug mandrels.

11 31 052 Replacing both timing chains (M47)
(for injection pump and camshaft drive)

refer to 11 14 110.
Removal:
Removal of both timing chains is described separately from installation.
Fit vibration damper (1) and tighten central bolt (2) by hand.
Grip central bolt (2) of vibration damper (1), slacken chain wheel nut (3)
and then retighten to 18 Nm.

Crank engine at central bolt in direction of rotation until piston of first
cylinder is in firing TDC position.
Locate flywheel with special tool 11 2 300 in firing TDC position of first
cylinder.
Release blocking screw (1) and remove spacer plate (2).

Retighten blocking screw (1) to 31 Nm.
The injection pump is now blocked and cannot be rotated anymore.
Caution!
If the injection pump is rotated while the blocking screw (1) is
tightened, the pump will be damaged and will have to be replaced.
Slacken chain wheel nut (3).

Release central bolt (2) and remove vibration damper (1) again.
Press in clamping piston at bottom and lock with special tool 11 3 340
(alignment pin).
Warning!
When plug pins are removed, there is a risk of injury.
Release screw (1) and remove guide rail (2).

Remove tensioning rail (1).
Remove chain wheel nut (1).
Screw special tool 13 5 190 onto injection pump chain wheel and press
off chain wheel with forcing screw.
Remove both sprocket wheels with chain attached.

Installation:
Installation of both timing chains is described separately from removal.
Check parallel key of crankshaft for damage and correct installation

position.
Note:
The position of the chain wheel for the injection pump does not
influence the function in any way.
Align crankshaft chain wheel to parallel key of crankshaft.

Force both chain wheels with fitted chains together onto crankshaft and
injection pump shaft.
Fit chain wheel nut (1) on injection pump shaft and tighten so that it is
free of play.Caution!
Do ”not” tighten down chain wheel nut (1).
Install tensioning rail (1).
Install guide rail (2), insert and tighten down screw (1).
Press in clamping piston at bottom and remove special tool 11 3 340

(alignment pin).
Fit vibration damper (1) and tighten central bolt (2) by hand.
Tighten chain wheel nut (3) to initial torque of 18 Nm.
Slacken blocking screw (1).
Install spacer plate (2) and tighten down blocking screw (1).
Tightening Torque,
Position special tool 11 6 310 on vibration damper (1). Protect engine

bracket from damage. Insert wood between engine support and special
tool 11 6 310. Tighten central bolt (2) to approx. 150 Nm.
Tighten down chain wheel nut (3).
Tightening Torque of chain wheel nut (3),
Release central bolt (2) and remove vibration damper (1) again.
refer to 11 14 110.
Crank engine again to 45° before firing TDC position for first cylinder.
Note:
If the engine has been cranked and the firing TDC position of the
injection pump for the first cylinder is no longer known, it can be
sought for via the setting value of the injection pump.
The procedure is described in the work step Removing and installing
cylinder head,
refer to 11 12 100.
11 31 052 Replacing both timing chains (M47TU)
This task is described in the section ”Removing and installing front timing
casing cover”.Note:
For drive of camshaft and H.P. pump.
11 31 001 Replacing camshafts (M47)

00 9 120
11 2 300
11 3 340
11 6 320
11 6 322
Remove vacuum pump.

E46 with manual transmission:
Remove fan cowl.
Removal:
Removal of camshafts is described separately from installation.

Release plug in lower timing case cover.
Slowly and carefully rotate exhaust camshaft at hexagon drive in

direction of rotation until hydraulic chain tensioner is compressed.
Lock hydraulic chain tensioner with special tool 11 3 340 .Note:

If one or both chain wheel(s) is/are removed without a locked
hydraulic chain tensioner, the chain tensioning piston slips out and
can only be compressed again after considerable effort.
Release screws, feed guide rail (1) out of guide rail (2) and remove.
Set up special tool 11 6 322 from special tool kit 11 6 320 with
commercially available screws.
Lock inlet camshaft with special tool 11 6 320 .

Note:
When releasing camshaft screw connection, grip camshafts at
hexagon drive.
Slacken screw (1).

Slacken screw (2).
Remove screw (1).
Note:
Remove exhaust chain wheel through opening for vacuum pump.
Do not damage sealing surface.
Feed out timing chain, remove exhaust chain wheel.
Remove previously slackened screw (2). Feed out timing chain, remove
inlet chain wheel.
Caution!
To prevent damaging valves when fitting the camshafts, no pistons
should be in TDC position.

Release screws (1) of camshaft bearing caps in 1/2 turn increments

evenly from outside to inside.
Remove bearing caps and lift out camshafts.
Note:
Worn rockers may only be reused on the same grooves of the
camshaft.
Remove rockers and put down in orderly fashion.

Caution!
These screws must "not" be removed.
Installation:
Installation of camshafts is described separately from removal. The
assembly sequence differs between removal and installation.
Note:
Lubricate camshafts, bearings and bearing caps prior to installation.
Note:
camshaft.
Install rockers.
Note:
E Inlet camshaft
A Exhaust camshaft
Install camshafts.
The bearing caps of the inlet camshaft are marked E 1 ... E 5 from the
exhaust side.
The bearing caps of the exhaust camshaft are marked A 1 ... A 5 from the
exhaust side.
Fit bearing caps.
Insert all screws (1) and initially tighten so that they are free of play.
Tighten down camshaft bearing caps in 1/2 turn increments evenly from
inside to outside.
Tightening torque,
Note:
Rotate camshafts at hexagon drive.
Rotate camshafts until cam tips of inlet and exhaust camshafts point to
each other.
Remove plug from alignment bore.

Rotate engine from position of 45° before TDC in direction of rotation to
TDC position.
Caution!
Remove special tool 11 2 300 before starting engine.
Align inlet camshaft and locate with special tool 11 6 320 in firing TDC
position of first cylinder.
Feed inlet chain wheel onto timing chain and attach to inlet camshaft.
Replace chain wheel screw (1).
Insert chain wheel screw (1), tighten and then slacken again by a half
turn.
Note:
The position of the chain wheel to the camshaft does not influence
the function in any way.
Install exhaust chain wheel through opening for vacuum pump. Do not
damage sealing surface.
Feed exhaust chain wheel onto timing chain and attach to exhaust
camshaft.
Insert new chain wheel screw (2) and tighten.
Note:
The position of the chain wheel to the camshaft does not influence
the function in any way.
Feed guide rail (1) into guide rail (2), insert and tighten down screws.
Slowly and carefully rotate exhaust camshaft at chain wheel screw in

direction of rotation until hydraulic chain tensioner is compressed.
Withdraw special tool 11 3 340 .

Install screw plug and tighten down.
Tightening torque,
Slacken chain wheel screw (2) on exhaust chain wheel again by a half
turn.
Note:
When tightening camshaft screw connection, grip camshafts at
hexagon drive.
Tighten down inlet chain wheel with special tool 00 9 120 .
Tightening specifications,
Align exhaust camshaft and locate with special tool 11 6 320 in firing TDC
position of first cylinder.
Note:
When tightening camshaft screw connection, grip camshafts at
hexagon drive.
Tighten down exhaust chain wheel with special tool 00 9 120 .
Tightening specifications,
Pull back special tool 11 2 300 until flywheel is no longer located in

position.
Caution!

Fit special tool 11 6 320 to exhaust camshaft.Note:


Install plug in alignment bore.
Assemble engine.
11 31 001 Replacing camshafts (M47TU)

00 9 120
11 2 300
11 3 340
11 6 320
Remove vacuum pump.

E46 with manual transmission:
E46 with automatic transmission:
Remove fan cowl.
Removal:
Removal of camshafts is described separately from installation.

firing TDC position.Note:
Pay attention to position of cams (1).
Undo plug in timing case cover at bottom.
Rotate exhaust camshaft (A) at hexagon head slowly and carefully in

direction of arrow until hydraulic chain tensioner is compressed.
Lock hydraulic chain tensioner with special tool 11 3 340 .Note:

If sprocket wheels are removed without the hydraulic chain
tensioner being locked, the chain tensioning piston slips out and
can only be pressed back in with considerable effort.
Release bearing pins (1) of guide rails.

Release sprocket wheel screw (3).
Note:
Grip hexagon head of inlet camshaft (5) in so doing.
Lift off sprocket wheel (4) with chain.
Pull out guide rail (2).
Detach chain from sprocket wheel.
Remove sprocket wheel.
Lift off gear wheel of inlet camshaft.
Release screw connection of exhaust camshaft.
Note:
Grip hexagon head of exhaust camshaft (8) in so doing.
Remove bushing and gear wheel of exhaust camshaft (7).
Caution!
To prevent damaging valves when fitting the camshafts, no pistons
should be in TDC position.

Release screws (1) of camshaft bearing cap in 1/2 turn increments

evenly from outside to inside.
Remove bearing caps and camshafts.
Note:
camshaft.
Remove rockers and put down in orderly fashion.

Caution!
These screws must ”not” be removed.
Installation:
Installation of camshafts is described separately from removal. The
assembly sequences for installation and removal are different.
Note:
Lubricate camshafts, bearings and bearing caps prior to installation.
Note:
camshaft.
Insert rockers.
Note:
E Inlet camshaft
A Exhaust camshaft
Insert camshafts.
Inlet camshaft bearing caps are marked E 1 ... E 5 from exhaust side.
Exhaust camshaft bearing caps are marked A 1 ... A 5 from exhaust side.
Fit bearing caps.
Insert all screws (1) and initially tighten so that they are free of play.
Tighten down camshaft bearing caps in 1/2 turn increments evenly from
inside to outside.
Note:
Rotate camshafts at hexagon head (2).
Rotate camshafts until cams are roughly situated in position shown in

illustration.

Remove plug from special tool bore.
Crank engine from 45° before TDC position in direction of rotation up to
TDC firing position.
Secure crankshaft with special tool 11 2 300 in TDC position.
Caution!
Remove special tool 11 2 300 before starting engine.
Align inlet camshaft and secure with special tool 11 6 320 in firing TDC
position of first cylinder. Fit gear wheel of inlet camshaft.Installation:
Bearing pins must be replaced.
Installation:
Replace camshaft screw (3).
Insert guide rail (2).

Screw down screw pins on guide rails.
Fit sprocket wheel with timing chain.
Insert camshaft screw (3), tighten by hand and then release again by half
a turn.
Note:
The position of the sprocket wheel to the camshaft does not
influence the function in any way.
Install gear wheel and bushing of exhaust camshaft (7).Installation:

Replace camshaft screw (6) and tighten by hand.
Rotate exhaust camshaft (A) at its hexagon head slowly and carefully in
direction of arrow until hydraulic chain tensioner is compressed.
Pull out special tool 11 3 340 .

Insert plug and tighten down.
Slacken camshaft screw (6) on exhaust camshaft again by a half turn.

Note:
When tightening down camshaft screw connection, grip camshafts
at their hexagon head.
Tighten down inlet sprocket wheel with special tool 00 9 120 .
Align exhaust camshaft and secure with special tool 11 6 320 in firing TDC
position of first cylinder.Note:
When tightening down camshaft screw connection, grip camshafts
at their hexagon head.
Tighten down exhaust gear wheel with special tool 00 9 120 .

position.
Caution!
Secure crankshaft with special tool 11 2 300 in TDC position.
Place special tool 11 6 320 on inlet camshaft.

Note:
Repeat the work operation under the same requirements on the exhaust
camshaft.
Remove special tool for securing and checking camshaft positions.

Install plug in special tool bore.
Assemble engine.
11 34 715 Replacing all valve springs (M47 / M47TU)

11 0 342
11 0 346

Preliminary tasks are described in Disassembling and assembling
cylinder head.
Align special tool 11 0 346 in direction of valve shaft. Select

corresponding groove in special tool 11 0 342 .
Press down valve spring at spring plate at top with special tool 11 0 342
and hook in.
Remove valve cones.

Remove valve spring and spring plate.
Installation sequence:
1. Valve
2. Valve-stem seal
3. Valve spring
4. Top spring plate
5. Valve tapers
11 34 560 Replacing all valve stem seals (M47 / M47TU)

11 1 960
11 6 370
11 6 380

Preliminary tasks are described in Disassembling and assembling
cylinder head.
Remove all valve springs.
Press special tool 11 6 370 onto valve stem seal and turn.
Remove special tool 11 6 370 together with valve stem seal.
Lubricate valve stem and fit special tool 11 1 960 .

Coat new valve stem seal (1) with oil and install.

Press on valve stem seal with special tool 11 6 380 as far as it will go.
11 40 000 Checking engine oil pressure (M47)

11 4 050
13 3 061
13 3 063
13 6 051
13 6 054
Caution!

malfunction.
Note:
To prevent excessive oil discharge when the oil pressure switch is
removed, it is essential to drain the main flow oil filter.
Caution!
with socket only.
When the main flow oil filter cover is released, the engine oil flows
from the oil filter housing back into the sump.
Release main flow oil filter cover and take off.
Replace sealing rings and coat with oil.

Fit main flow oil filter cover and tighten down.
E46 only:
Release screws.
Note:
E39 only:
Release screws.
Release screws.
E46 and E39:
Caution!
A small amount of engine oil emerges when the oil pressure switch
is removed. Have a cleaning cloth ready.
Disconnect plug connection (1) and remove oil pressure switch (2).
Installation:
Install special tool 11 4 050 with sealing ring (1) in place of oil pressure
switch.
Checking engine oil pressure with DIS Tester:

Attach special tool 13 6 054 with sealing ring (1) and special tool 13 6 051
and connect to DIS Tester.
Checking engine oil pressure with pressure gauge:
Install special tool 13 3 063 and special tool 13 3 061 (pressure gauge).
Check engine oil pressure.
Specified value.
11 40 000 Checking engine oil pressure (M47TU / M47T2)

11 4 050
13 3 061
13 3 063
13 6 051
13 6 054
To prevent excessive oil discharge when the oil pressure switch is

removed, it is essential to drain the main flow oil filter.
Important!
malfunction.
Important!
with socket only.
When the main flow oil filter cap is opened, engine oil flows from the
oil filter housing back into the oil sump.
Release main flow oil filter cap and remove towards top.

Important!
Small amounts of engine oil may emerge when the oil pressure
switch is removed. Have a cleaning cloth ready.
Disconnect plug connection and remove oil pressure switch.Installation:

Install special tool 11 4 050 with sealing ring (1) in place of oil pressure
switch.
Check engine oil pressure with DIS Tester

Attach special tool 13 6 054 with sealing ring (1) and special tool 13 6 051
and connect to DIS Tester.
Check engine oil pressure with pressure gauge
Install special tool 13 3 063 and special tool 13 3 061 (pressure gauge).
Check engine oil pressure.
Specified value.
Reassemble car and set in horizontal position.
11 41 000 Installing and removing or replacing oil pump (M47)
Remove both timing chains,

refer to 11 31 052.
Remove intake neck of oil pump.Installation:

Clean sealing face and replace seal.
Release oil pump screws and remove oil pump.
Lift out parallel key (1).
Installation:
Clean sealing face and replace seal.
Check adapter sleeves (1) for timing case cover at bottom for
damage and correct installation position.
Installation:
Center oil pump to crankshaft with special tool kit 11 4 200
consisting of special tools 11 4 201 / 202 and 203:
Fit oil pump and align to crankshaft with special tool 11 4 201 and
11 4 202. Insert special tool 11 4 203 by hand as far as it will go, then
insert and tighten down screws for oil pump.
If necessary, dismantle oil pump and reassemble.Note:

Intake neck is secured to oil pump with self-tapping screws.
For this reason, there is no thread on new pump housings.
Thread can be shaped using existing screws.
Unfasten screws and lift off cover.Note:

Screw (1) with M7 thread.
Remaining three screws with M6 thread.
Installation:
Tighten down all four screws to 9 Nm.
Check housing and cover for signs of wear and fretting

corrosion.Installation:
Bevel on outer rotor points towards housing.
Press sleeve downwards gently using suitable mandrel.

Caution!
Strong spring force.
Lift out retaining ring and remove pressure valve.

Installation:
1. Piston
2. Spring
3. Sleeve
4. Check O-ring, replace if necessary.
5. Circlip
11 41 000 Removing and installing or replacing oil pump (M47TU / M47TU2)

11 2 300
11 3 340
11 5 180
Remove oil sump.
Release screws on oil pump and remove oil pump.
Important!
A removed oil pump must not be reused. It must always be replaced.
The new oil pump gear is partially coated with paint for problem-free
adjustment of the tooth backlash.
Installation:
M47TU:
Crankshaft and balancing shaft must be positioned towards each other.
Set engine with special tool 11 2 300 .
Installation:
M47TU2:
Crankshaft and balancing shaft must be positioned towards each other.
Set engine with special tool 11 5 180 .
Set balancing shaft unit with special tool 11 3 340 or with a mandrel
(d=5 mm).
Installation:
Use new, degreased and deoiled screws.
Tapped holes on balancing shaft unit must also be degreased and
deoiled.
Installation:
Fit new oil pump.
Make sure the painted partial surface of the idler gear of oil pump (1)
meshes with the drive gear of crankshaft (3) and the gear of balancing
shaft (2).
For this purpose, both marker points on the idler gear of oil pump (1)
point simultaneously towards the drive gear of crankshaft (3) and the
gear of balancing shaft (2).
Screw in bolts by hand and then unscrew one turn (oil pump can be
easily moved).
Press oil pump simultaneously in axial direction (dark arrow) and in radial
direction (light arrow) against crankshaft drive gear and balancing shaft
gear. (Refer to picture document).
Pretighten screws according to number sequence.
Tighten down screws in same sequence.
Important!
Screws (1 and 4) with M6 threads.
Screws (2 and 3) with M7 threads.
Remove setting mandrels as required.

11 42 020 Removing and installing/sealing or replacing complete main flow
oil filter (M47)

00 0 200
00 0 201
00 0 202
00 0 204
00 0 208
Warning!
Danger of injury!
The main flow oil filter and the engine support arm form a single
component.
Before removing main flow oil filter:
Support engine against falling with special tool 00 0 200 .
Caution!

malfunction.
Note:
Release screws.
Unclip hoses.
Remove hose holder (1).
Release screws.
Installation:
Remove main flow oil filter cover, remove oil filter element and drain off
engine oil.

Drain and dispose of coolant,
refer to General Information for working on cooling system.
Installation:
Replace seal.
Cooling system must be topped up, vented and checked for leaks.
Release hose clamps (1 and 2) and detach water hoses from oil-water
heat exchanger.
Assemble special tool 00 0 200 with special tool 00 0 201 / 00 0 202

/ 00 0 204 / 00 0 208 and install.
Note:

Release nut on left engine mount.
Release support bracket between timing case cover and main flow
oil filter.
Release guide tube for oil dipstick from timing case cover.
Remove plug from oil pressure switch.
Remove main flow oil filter housing from engine block (four screws).
Installation:
Clean sealing surface on engine block.
If necessary, remove oil-water heat exchanger from main flow oil filter.
Installation:
Clean sealing surfaces.
Replace seals (1 and 2).
Assemble engine.
11 42 020 Removing and installing/sealing or replacing complete main flow
oil filter (M47TU / M47T2)
Important!

malfunction.
Note:
The preliminary work for removing the main flow oil filter is described in
the repair instruction
Removing oil-water heat exchanger.
Note:
For E46 automatic:
Remove fan cowl.
Note:
For E46 manual:
Remove main flow oil filter cover, remove oil filter element and drain off
engine oil.

Drain and dispose of coolant.
Installation:
Replace seal.
Cooling system must be topped up, vented and checked for leaks.
Release clamp from intake pipe on exhaust gas recirculation valve

(EGR).
Detach clamp from EGR cooler/pipe.
Installation:
Release cable.
Disconnect plug from electropneumatic pressure transducer (EPPT) for
exhaust gas recirculation valve (EGR).
Release screws (arrow).
Remove EGR valve.
Detach coolant hose on engine side from quick-release coupling
and place to one side.
Note:
Illustration of removed line
Disconnect all quick-release couplings on coolant connecting line.
Release the two retaining screws.
Release oil dipstick guide tube on manifold. Do not remove guide

tube.
Remove plug from oil pressure switch.
Detach vacuum hoses from EPPT.
Remove main flow oil filter housing from engine block (four screws).
Installation:
Clean sealing surface on engine block.
Installation:
Replace seals (1 and 2).
Assemble engine.
11 44 000 Removing and installing, sealing or replacing oil-to-water heat
exchanger (M47TU / M47T2)
Important!

malfunction.

Drain off and top up coolant.
Disconnect and cover battery negative lead.
Remove acoustic cover.
Remove microfilter housing.
Important!
with socket only.
When the main flow oil filter cover is released, the oil flows from the
oil-water heat exchanger back into the sump.

Tightening torque of 25 + 5 Nm is stamped on cover.

Pull out oil filter element (1) and replace.Installation:
Press oil filter element (1) onto support in oil filter housing.

Unclip hoses.
Release profile seals (3).
Release locks () and remove side trim panel.
Release hose clamps (1).

Detach water hoses from oil-water heat exchanger.
Detach glow control unit including retaining bracket and place to one side.
Release screw on oil-water heat exchanger.

Remove oil-water heat exchanger.
Installation:
Replace seal.

Switch off engine. Wait approx. 10 minutes and check engine oil level.
11 44 000 Removing and installing/sealing or replacing oil-water heat
exchanger (M47)
Caution!

malfunction.
Note:
Switch off ignition.
Follow instructions for disconnecting and connecting battery.
Follow instructions for working on cooling system.

Caution!
with socket only.
When the main flow oil filter cover is released, the oil flows from the
oil-water heat exchanger back into the sump.
Release main flow oil filter cover and take off.

Pull out oil filter element (1) and replace.Note:

E46 only:
Unclip hoses.

Release screws.
Note:
E39 only:
Release screws.
Release screws.
E46 and E39:

Release screws.
Installation:
Release hose clamps (1 and 2).

Detach water hoses from oil-water heat exchanger.
Release screw (1) on oil-water heat exchanger.
Release screws (2 and 3) on oil-water heat exchanger.

Remove oil-water heat exchanger.
Installation:

Switch off engine. Wait approx. 10 minutes and check engine oil level.
11 51 000 Removing and installing or replacing water pump (M47)
Installation note:
1. All screws, nuts, bolts and hose clamps removed during the repair
must be replaced.
2. Retaining elements on chassis and suspension and steering parts
must be replaced.
Remove drive belt for alternator,

refer to 11 28 010.
Important!
alternator against dirt contamination.

malfunction.
Important!
If the charge air hoses are not fitted dry and without grease, this will
Fit charge air hoses dry and without grease.
Drain and dispose of coolant.Installation note:

Replace gasket.
Tightening torque,
Top up, bleed and check cooling system for watertightness,
refer to 17 00 005.
Release screw of coolant connecting line.Note:

Screw with thread M7.
Installation note:
Tightening torque,
Remove charge air hose from exhaust-gas recirculation valve.
Installation note:
Release screw (1).

Pull lock (2) and pull off water hose.
Installation note:
Refer to general notes for repair work on cooling system.
Release screws and remove water pump.
Installation note:
Clean sealing faces.
Check fitting sleeves (1) for damage and correct installation
position.
Replace gasket (2).
Note:
Screw with thread M7.
Installation note:
Tightening torque,
11 51 000 Removing and installing/replacing the coolant pump
(M47TU/M47TU2/M57TU/M57T2/)
Important!
Installation note:
must be replaced.
must be replaced.

Remove and install the coolant thermostat.
Release screws (1).

Remove water pump (2).
The sealing surface on the crankcase must not be damaged during

the following repair work.
Cut off connecting bridges (1) of gasket (2) accordingly.

Important!
Do not damage sealing surface.
Cut through connecting bridges (1) of gasket (2) with a small cross-cut
chisel (3).
Remove gasket.
Clean sealing surface.
Installation note:
Before installation, first position new gasket on sealing surface on
crankcase and check for correct fit.
Assemble engine.
Vent the cooling system and check for leaks.
11 52 020 Removing and installing/replacing fan clutch (M47 / M47TU / M57 /
M57TU)

11 5 040
Remove fan cowl.
Caution!
Do not damage radiator fins.
The fan clutch is secured to the water pump with a left-hand thread.
To release fan impeller:

- Grip water pump at square drive.
- Detach fan impeller with special tool 11 5 040 .
Installation:
When using special tool 11 5 040 , 30 Nm on the torque wrench scale are
equivalent to a tightening torque of 40 Nm.
Attach special tool, as illustrated, to torque wrench.
Release screws.
Detach fan impeller from fan clutch.
11 53 000 Removing and installing or replacing coolant thermostat (M47)
Caution!

malfunction.
Caution!
Remove EGR cooler,

refer to 11 71 100.
Note:
Thermostat for EGR cooler must not be removed.

Replace seal.
Tightening Torque,
Fill cooling system, vent and check for leaks,
refer to 17 00 005.
Pull lock (1) and detach water hoses.Installation:

Release screw on coolant connecting line.Note:
Screw with M7 thread.
Installation:
Tightening Torque,
Disconnect charge air hose from EGR valve.

Installation:
Unscrew bolt (1).

Pull lock (2) and detach water hose.
Release screws on thermostat housing, remove thermostat housing.
Note:
The coolant thermostat is integrated in the coolant thermostat
housing and can only be replaced as a complete unit.
Installation:
Keep sealing faces clean and free of oil.
Replace gasket (1).
11 53 000 Removing and installing or replacing coolant thermostat (M47TU /
M47T2)
Important!
Bolted charge air hoses must be fitted dry and free from grease.

Detach upper charge air hose.
Remove and install A/C compressor drive belt.
Remove and install alternator drive belt.
Release clamp (1) on EGR pipe.

Release screw (2).
Release screws (3) and press heat shield in direction of arrow.
Remove EGR pipe.
Detach heater delivery line.
Note:
In car with automatic transmissions, remove EGR cooler.
Lever out lock (1)

Lever out lock (2)
Installation:
Release screws (3) on thermostat housing. Remove thermostat

housing.
Note:
Coolant thermostat is integrated in coolant-thermostat housing and
can only be replaced as a complete assembly.
Installation:
Replace seal (1).
Assemble engine.
11 12 800 Cleaning cylinder heat intake channels and intake plenum (M47,
M57)

11 2 300
11 5 180
11 6 080
2 356 969
2 356 970
2 356 968
2 356 967
2 356 966
00 9 120
11 6 480

Clamp off battery
Detach the injector wiring harness from the cylinder head
cover
Remove the electric fan if necessary
Attention!
Electric swirl-flap controller must not be removed!
Never place electrical components in cleaning bath!
Do not place pneumatic swirl-flap controller in cleaning bath!
Dismantle the intake plenum (remove exhaust-gas recirculation valve,

throttle valve, pneumatic swirl-flap controller and charging pressure
sensor).
Prepare cleaning bath with 1 part BMW universal cleaner (see Section
3.2) and 2 parts water.
Place intake plenum in cleaning bath. Leave to soak at least 1 hr.
Note: Place the intake plenum in the cleaning bath so that the
electric swirl-flap controller is not lying in the bath.
Crank engine to cylinder no. 1 TDC setting:
Unlock and disconnect plug (1) as required.
Loosen screw.
Remove pulse sensor (2).
Installation note:
Check sealing ring (1) for damage and replace if necessary.
Note:
Shown with cylinder head cover removed for enhanced clarity.
Figure M57TU.
Attention!
Look through camshaft position sensor opening or oil filler cap opening to
conduct visual inspection.
Crank engine at central bolt.
The cam lobes (1) on the intake camshaft (E) at no. 1 cylinder point to
the right as viewed toward the front when engine is at TDC setting.
Remove protective cap in direction of arrow.Installation note:

Reinstall protective cap with some grease.
M47, M47TU, M57, M57TU:
Use the central bolt to turn over the engine, rotating the crankshaft in the
normal direction of rotation, continuing until the piston in no. 1 cylinder is
at TDC setting.
M47T2, M57TU2:
Use the central bolt to turn over the engine, turning crankshaft in the
normal direction of rotation, and continuing until the piston in no. 1
cylinder is at TDC setting.
M57T2, M57T2SCR:
Crank engine at central bolt in direction of rotation until piston of 1st
cylinder is in TDC setting.
Secure the crankshaft in the TDC setting with special tool 11 6 080 .
Attention!
Special tool 11 6 080 must be removed before starting the engine.
Cleaning intake ports: Attention!

Risk of engine damage!
The intake valves of the corresponding cylinder must be closed
when cleaning the intake ports.
Start with the 1st cylinder when cleaning the intake ports.
The following are required:
Blasting tool 81 29 2 208 034
Walnut shell granulate
Vacuum cleaner
Attention!
Front area of sensors is marked with two notches. These can
additionally be highlighted in colour.
During the blasting process, only pull the wands out of the vacuum
adapter until the mark becomes visible.
Blasting wand for tangential swirl port:

2 356 969
Blasting wands for swirl port:
2 356 970 with straight outlet
2 356 968 with lateral outlet
Vacuum adapter for tangential swirl port:

2 356 967
Vacuum adapter for swirl port:
2 356 966
Note:
Open blasting tool (1) and pour in 2 litres of granulate (2).

Close the device again.
Note:
Operating pressure 6 - 8 bar.
Close main valve (1) on blasting tool (2).

Connect compressed air (3).
Cleaning the tangential swirl port of 1st cylinder:

Screw together blasting wand 2 356 969 (1) and actuator (2).
Note:
Actuator (3) has two stages!
In stage one, only compressed air flows through the blasting wand.
In stage two (operation is fully pressed), granulate is added (blasting
process).
Attention!
Danger of injury!
Risk of damage!
visible.
Connect vacuum cleaner (1) to vacuum adapter 2 356 967 (2). Hold
vacuum adapter 2 356 967 against swirl port at no. 1 cylinder.
Open the main valve on the blasting tool and switch the vacuum cleaner
on.
Insert blasting wand (3) into the adapter (2).
Open the actuator valve (4).
Slide locking lever (1) to the front in direction of arrow.
Operate compressed-air valve (2) at stage one; compressed air can now
flow in.
Fully operate valve (3) at stage two; walnut shell granulate is now
injected.
Clean intake port, rotating the blasting wand and moving it vertically up
and down.
Blasting wand may only be pulled out until the mark becomes visible.
When you notice that the container is becoming empty, continue
operation for at least 10 seconds at stage one in order to swirl up and
draw off the remaining granulate.
device).
Cleaning the swirl port of 1st cylinder:

Attention!
Risk of damage!
Plastic section (1) of the swirl port must not be blasted.
Before blast-cleaning, mechanically clean the plastic section of the swirl

port (1) in the cylinder head cover (e. g. using a plastic scraper, brushes
83 19 2 298 237 or similar tools).
Note:
Two blasting wands must be used for the swirl port.
This means that two individual cleaning operations are necessary.
Attention!
Danger of injury!
Risk of damage!
visible.
Swap over vacuum adapter 2 356 966 (1) and blasting wands (2).
Carry out one complete cleaning operation (identical to that for cleaning
the tangential swirl port) with blasting wand2 356 968 and then one
complete cleaning operation with blasting wand 2 356 970 .
To prevent damage to the cylinder head cover, the blasting wand should
never be pulled out further than the marking!
device).
Check that there is no granulate residue in both intake ports; if
necessary, draw off/blow out.
Cleaning the other cylinders:

Attention!
Remove special tool for securing the crankshaft.

Proceed in the standard firing order while using the same procedure to
clean the swirl ports at the remaining cylinders.
Firing order:
1 3 4 2 (4-cylinder engine)
1 5 3 6 2 4 (6-cylinder engine)
During this operation use 00 9 120 and 11 6 480 to turn the central bolt
180° (4-cylinder engine) or 120° (6-cylinder engine).
Remove the intake plenum from the cleaning bath.

Clean plenum openings and swirl flaps with brush set (1) part
number: 83 19 2 298 237.
Use brust set to clean the throttle valve, exhaust-gas recirculation valve
and the mounted parts.
Attention!
Do not clean electrical components with a component washing
machine or high pressure cleaner.
Protect electric swirl-flap controller against splashing water as
necessary!
Cover electric swirl-flap controller appropriately as necessary!
Then clean the plenum with a parts washer or a high-pressure cleaner.
Crank motor at central bolt at least twice.

Assemble engine.
Reset correction values at
Reset service function - 01 drive - DDE - Reset correction values of
injectors.
11 61 050 Removing and installing intake air manifold (M47)
Remove microfilter.
cable(s).
Release screws (1), remove lower section of microfilter housing (2) and
underlying heater bulkhead,
refer to 51 71 080.
Note:
Screw (1) not visible.
Release screws, lift off front acoustic cover.
Remove intake neck.
Note:
Screw (1) is not visible in vehicle.
Release screws, lift off cover.

Unclip hoses, remove hose holder (1).

Release screws, remove left acoustic cover.
Installation:
Check rubber grommet for accommodating left acoustic cover in oil
filter housing, replace if necessary.
Guide pins of left acoustic cover must be joined in rubber grommet
on oil filter housing and in bore of rear acoustic cover.
Release screw of rear acoustic cover to intake air manifold.
Note:
Illustration is shown without intake pipe to EGR valve. Intake pipe on
EGR valve must not be removed.
Detach EGR valve from intake air manifold.
Lift out acoustic cover.
Note:
The nuts (1) fall out very easily during removal and installation, use
special tool 00 2 190 if necessary.
Unfasten screws (2) and nuts (1).

Note:
The intake air manifold is vibrationally separated by rubber mounts
and seaks from the cylinder head and cylinder head cover.
Installation:
Replace sealing rings (1) in intake air manifold.
Check rubber mount (2), replace if necessary.
Installation:
Fit intake air manifold.
Note:
Nuts (1) with M7 thread.
Screws (2) with M6 thread.
Insert nuts (1) and tighten to initial torque of approx. 10 Nm. Insert
screws (2).
Tighten down nuts (1).
Tighten down screws (2).
11 61 050 Removing and installing intake air manifold (M47TU / M47T2)

Disconnect battery terminal.
Disconnect lead from battery positive terminal.
Remove lower microfilter compartment.
Remove front and rear acoustic insulation panels.
Detach dipstick from intake manifold.
Disconnect plug connection at charge-air pressure sensor.
Detach vacuum line and plug connection from electric valve.
Unfasten release element (1) in direction of arrow.

Release pressure pipe (2) in direction of arrow.
Detach EGR tube from EGR valve.
If necessary, disconnect plug connection on electronic throttle valve.
Unfasten screws (2).

Unscrew nuts (1).
Installation:
Nuts (1) may fall out slightly during removal and installation.
Installation:
Replace sealing rings (1).
Assemble engine.Note:
Intake manifold is vibrationally isolated by rubber mounts and seals from
the cylinder head and cylinder head cover and these parts must always
be replaced.
11 61 050 Removing and installing intake air manifold (M47TU)

00 2 190
Remove microfilter.
cable(s).
heater bulkhead underneath.

Unfasten screws.
Unfasten screws.
Open battery terminal housing.

Release nut.
Disconnect cable from terminal.
Unfasten screws.
Detach injector plug.
Lay injector wiring to one side.
Release clamp.
Disconnect pressure hose.
Unclip cable.
Release four screws of EGR valve.
Detach plug and hose connections on manifold.
Note:
(Changeover valve for swirl flaps and with engines with manual
transmissions switchover valve for radiator shutter / plug connection for
boost pressure sensor.)
Detach grommet from line to pressure regulator.

Release oil dipstick guide tube on manifold.
Do not remove guide tube.
Note:
Unfasten screws (2) and nuts (1).

(Illustrations show M47 engine)
Note:
The intake air manifold is vibrationally separated by rubber mounts
and seals from the cylinder head and cylinder head cover.
Installation:
Replace sealing rings (1) in intake air manifold.
Installation:
Fit intake air manifold.
Note:
Screws (2) with M6 thread.
Insert nuts (1) and tighten to initial torque of approx. 10 Nm. Insert
screws (2).
Tighten down nuts (1).
11 61 350 Removing and installing/replacing left pressure pipe (charge air
hose) (M47TU / M47T2)
Important!
Pressure pipes cannot be fitted without anti-friction agent.
Damaged shaped sealing rings will result in a pressure loss, risk of
damage to turbocharger.

Unlock locking clip (1) in direction of arrow.

Release pressure pipe at points (1).

Detach cable from retainer (2).
Installation:
Visually inspect shaped sealing ring (1) for correct seating and damage.
Coat all mounting fittings with anti-friction agent (2). Refer to Technical
Data.
Lock locking clip (4).
Attach pressure pipe (3) in direction of arrow.
Installation:
VDA couplings are correctly fitted when they snap into place with an
audible click.
Check function of DDE.
Check pressure pipe for leaks.
11 61 350 Removing and installing/replacing left pressure pipe (charge air
hose) (M57TU)
Important!


Release pressure pipe at points (1).

Detach cable from retainer (2).
Installation:
Visually inspect shaped sealing ring (1) for correct seating and damage.
Data.
Lock locking clip (4).
Installation:
VDA couplings are correctly fitted when they snap into place with an
audible click.
11 61 360 Removing and installing/replacing right pressure pipe (charge air
hose)

Remove underbody protection.
Remove intake hose.
Important!
Note:
Do not release screw (2).
Release screw (1).

Turn retaining ring in direction of arrow.
Remove pressure pipe.

Installation:
Visually inspect shaped sealing ring for correct seating and damage.
Data.
Lock locking clip on pressure pipe (2).
Installation:
VDA coupling is correctly fitted when it snaps into place with an audible
click.
Important!
11 61 360 Removing and installing/replacing right pressure pipe (charge air
hose)

Remove intake hose.
Important!
Note:
Do not release screw (2).
Unscrew bolt (1).

Turn retaining ring in direction of arrow.
Remove pressure pipe.

Installation:
Visually inspect shaped sealing ring for correct seating and damage.
Data.
Lock locking clip on pressure pipe (2).
Installation:
VDA coupling is correctly fitted when it snaps into place with an audible
click.
Important!
11 65 020 Removing and installing or replacing exhaust turbocharger
(M47TU)
Warning!
Risk of burning!
Only perform this repair work on an engine that has cooled down.
Attention!
If the charge air hoses are not fitted dry and without grease, this can
Note:
Troubleshooting on exhaust turbocharger.
Attention!
For exhaust turbocharger damage:
In order to avoid subsequent damage, the following
notes and test steps must be followed absolutely.

Remove fan cowl.
Remove air filter insert.
Remove primary catalytic converter.
Disengage cable and hose from intake pipe.

Release screws.
Pull off intake pipe with bypass hose.
Installation note:
Thinly coat sealing surfaces of sealing rings (1) with Vaseline.
Insert sealing rings (1) into the intake pipe.
Release screw (1).

Loosen screw (2).
Turn bracket in direction of arrow.
Release snap fastener on charge air cooler.
Fully remove charge air pipe/hose.
Attention!
- Fit charge air hoses dry and without grease.
- Immediately close the openings on the exhaust turbocharger
with a cap.
Release the banjo bolt.

Remove the engine oil pipe.
Note:
Close the connection of the engine oil line and bore hole on the
crankcase with a cap.
Installation note:
Replace the sealing rings.
Pull off vacuum hose from vacuum unit of exhaust

turbocharger.Installation note:
Layout of vacuum hoses.
Remove the sealing cap (1) from the thermal protection shield.
Pull the sealing plugs up and out.
Installation note:
The holding clip (1) on the sealing cap (2) must be inserted on the
thermal protection shield.
Installation note:
Replacing damaged sealing plugs.
Insert the three seal plugs (1) from the top.
Release screws (1).

Installation note:
Thinly coat thread of screws (1) with copper paste (CRC).
Attention!
To avoid damaging the threads and prevent exhaust turbocharger
leaks, insert the mounting bolts (1) in 1/2 turns simultaneously to
the stop.
Release the clamp (1) and remove the oil return line from the crankcase.
Release screws (2).
Remove the exhaust turbocharger towards bottom.
Note:
When replacing the exhaust turbocharger:
(figure similar)
Release banjo bolt from oil pressure line (1).
Remove oil pressure line (1).
Pour the additive for the exhaust turbocharger initial filling order number
83 19 2 362 168 into the bore hole for the banjo bolt of the new exhaust
turbocharger.
Crank exhaust turbocharger by hand several times.
Position the oil pressure line (1) on the new exhaust turbocharger.
Tighten the banjo bolt .
Installation note:
- Replace sealing rings.
- The oil pressure line (1) must be installed parallel to the housing
of the exhaust turbocharger.
Installation note:
- Replace all gaskets.
- Clean the sealing surfaces on the exhaust manifold.
11 62 000 Removing and installing, sealing/replacing exhaust manifold (M47)
Remove microfilter.
cable(s).

Slide covers approx. 2 cm towards rear and lift out.
Note:
Unfasten screws.
Remove intake neck.

Note:
Illustration with engine removed.
Lift out cleaner insert.
Installation:
Remove sealing cover (1) for heat shield, unclip plug (2).
Unfasten exhaust turbocharger.Installation:
Replace seal.
Coat screw threads with copper paste -CRC-.
Detach pipe for exhaust recuperation from exhaust manifold.
Release nuts (1), remove exhaust manifold.Installation:

Replace seals.
Note arrangement of heat-protection plates and seals; tab washers
face outwards.
Coat stud bolt threads with copper paste -CRC-.
Replace nuts.
11 62 000 Removing and installing, sealing/replacing exhaust manifold
(M47TU / M47T2)
Warning!
Scalding hazard!
Only perform these tasks on an engine that has cooled down.
Important! Charge air hose screwed into place.

Important!
Charge air hose inserted.
Remove fan cowl.

Release cable and hose on intake pipe.

Release screws.
Detach intake pipe with bypass hose.
Installation:
Apply a thin coat of petroleum jelly to sealing surfaces of sealing
rings (1).
Insert sealing rings (1) in intake snorkel.
Release screw (2).
Release screws (3) and remove heat shield.
Note:
Engines with EGR cooler: detach EGR cooler.
Release screw (1).

Slacken screw (2).
Turn fixture in direction of arrow.
Release quick-release coupling on intercooler.
Remove complete charge air tube/hose.
Important!
- Fit charge air hoses without grease and dry.
- Seal turbocharger openings with a cap immediately.
Remove sealing cover (1) from heat shield.

Pull out seal plug.
Installation:
Retaining clip (1) on sealing cover (2) must be inserted at heat
shield.
Installation:
Replaced damaged seal plugs.
Insert three seal plugs (1) from above.
Release screws (1).

Installation:
Apply a thin coat of copper paste (CRC) to screw (1) threads,
Slacken screws (2).
Installation:
Replace all gaskets.
Clean sealing faces on exhaust manifold.
Release all 8 nuts.
Remove exhaust manifold.
Installation:
Replace seals.
Apply a thin coat of copper paste (CRC) to screw threads.
refer to BMW Parts Service.
Replace nuts.
11 65 020 Damage on the exhaust turbocharger due to obstructed oil supply
lines
Caution!
If there is damage on the exhaust turbocharger:
Complaint:
Power loss, malfunction indicator lamp on
Damage to the exhaust turbocharger.
After damage to the exhaust turbochargers, the oil supply lines
are often not replaced and the oil is not changed, this can lead
to damage to the exhaust turbocharger again.
Further, fault code entries in the preheating system or to the
charging pressure controller (variable turbine geometry) are
not considered.
For N57X, additionally the following faults can be stored:
292200 Charging pressure controller (variable turbine
geometry): Position sensor in charging pressure controller
faulty or undervoltage 48F6 in charging pressure controller
(variable turbine geometry)
Attention: Subsequent damage is not covered by the
warranty!
Cause
The oil supply lines for the exhaust turbocharger are clogged
or blocked by oil sludge/coking. Due to that, oil supply to the
exhaust turbocharger may be inadequate and can cause
damage to the exhaust turbocharger again.
Malfunctions in the preheating system can lead to clogging of
the diesel particulate filter and thus to problems with the
charging pressure control or the charging pressure build-up.
Consequence: Problems at cold start or the engine does not
start due to a faulty preheating system. Power loss or
overheating of the exhaust branch.
If the new exhaust turbocharger is not filled with enough oil
prior to installation, the shaft bearings can be damaged at the
first starting operation itself.
Solution
Proceed as follows in response to a customer complaint:
If fault code entries are available for the preheating system,
the preheating system must be repaired. Then delete the fault
memory.
Caution!
If the engine does not heat up or only heats up very slowly
because of a defective thermostat, this can result in premature
or repeated damage to the exhaust turbocharger. Always
check the coolant thermostat and thermostat for the EGR
cooling if there is a complaint, and repair if applicable.
Engine oil and filter exchange must be carried out on the
engine absolutely, so as to guarantee operation of the
changed exhaust turbocharger with fresh oil!
Since the oil feed line as well as the oil return line may coke
with increased mileage especially in the cable connection area
of the exhaust turbocharger, the followings rules are
applicable:
Engines with one exhaust turbocharger:
Exhaust turbocharger exchange due to electrical fault on
the exhaust turbocharger (vehicle mileage/km up to
100,000 km):
Check the oil feed line, oil return line and the
associated banjo bolts for coking, replace if
applicable.
If the oil return line is replaced, the connecting pipe
on the crankcase must always be cleaned, as it is
also subject to coking!
If a replacement is not necessary: If the exhaust
turbocharger is offered only along with the oil return
line and oil feed line in the Electronic Parts
Catalogue (EPC), it can be removed from the order
list again.
Exhaust turbocharger exchange due to electrical fault on
the exhaust turbocharger (vehicle mileage/km starting at
100,000 km):
Replace the oil feed line, oil return line and the
associated banjo bolts.
Exchanging the exhaust turbocharger if there is
mechanical damage on the exhaust turbocharger:
Always replace the oil feed line, oil return line and
the associated banjo bolts.
Engines with several exhaust turbochargers:
Exchanging one or several exhaust turbochargers due to
electrical faults on the exhaust turbocharger (vehicle
mileage/km up to 100,000 km):
Check the oil feed lines, oil return lines and the
associated banjo bolts of all exhaust turbochargers
(including the intact exhaust turbocharger) for
coking, replace if applicable.
If all the oil return lines are replaced, all the
connecting pipes on the crankcase must always be
cleaned, as they are also subject to coking!
If a replacement is not necessary: If the exhaust
turbocharger is offered only along with the oil return
line and oil feed line in the Electronic Parts
Catalogue (EPC), it can be removed from the order
list again.
Exchanging one or several exhaust turbochargers due to
electrical faults on the exhaust turbocharger (vehicle
mileage/km starting at 100,000 km):
Replace the oil feed lines, oil return lines and the
associated banjo bolts of all exhaust turbochargers
(including the intact exhaust turbocharger).
Exchanging one or several exhaust turbochargers if there
is mechanical damage on the exhaust turbocharger:
Always replace the oil feed lines, oil return lines and
the associated banjo bolts of all exhaust
turbochargers (including the intact exhaust
turbocharger).
In case the diesel particulate filter is foul with oil, clean or
replace it, if necessary.
In order to exclude that the oil supply to the exhaust
turbocharger is not impaired due to faulty crankcase
ventilation, carry out a function check of the crankcase
ventilation in this regard. The corresponding test module can
be found in ISTA at:
Power train
Digital Diesel Electronics
Engine ventilation
Internal engine pressure
When installing the exhaust turbocharger, the exhaust
turbocharger itself needs to be filled to capacity with fresh
engine oil through the oil intake hole before the oil feed line
is mounted. Important: Never use liquid sealing compounds
when connecting the engine oil pipe as they can block the oil
ducts.
After installing the exhaust turbocharger, start the engine and
let it run at idle for 2 to 3 minutes before increasing the speed.
If required, initiate a regeneration of the diesel particulate filter
Important: For vehicles with N57x engines that have fault
memory entries that are at the top, a successful diesel
particulate filter regeneration must be carried out.
Then delete the fault memory.
11 65 020 Removing and installing or replacing exhaust turbocharger
(M47TU)
Warning!
Risk of burning!
Only perform this repair work on an engine that has cooled down.
Attention!
If the charge air hoses are not fitted dry and without grease, this can
Note:
Troubleshooting on exhaust turbocharger.
Attention!
For exhaust turbocharger damage:
In order to avoid subsequent damage, the following
notes and test steps must be followed absolutely.

Remove fan cowl.
Remove air filter insert.
Disengage cable and hose from intake pipe.

Release screws.
Pull off intake pipe with bypass hose.
Installation note:
Thinly coat sealing surfaces of sealing rings (1) with Vaseline.
Insert sealing rings (1) into the intake pipe.
Release screw (1).

Loosen screw (2).
Turn bracket in direction of arrow.
Release snap fastener on charge air cooler.
Fully remove charge air pipe/hose.
Attention!
- Fit charge air hoses dry and without grease.
- Immediately close the openings on the exhaust turbocharger
with a cap.
Release the banjo bolt.

Remove the engine oil pipe.
Note:
Close the connection of the engine oil line and bore hole on the
crankcase with a cap.
Installation note:
Replace the sealing rings.
Pull off vacuum hose from vacuum unit of exhaust

turbocharger.Installation note:
Remove the sealing cap (1) from the thermal protection shield.
Pull the sealing plugs up and out.
Installation note:
The holding clip (1) on the sealing cap (2) must be inserted on the
thermal protection shield.
Installation note:
Replacing damaged sealing plugs.
Insert the three seal plugs (1) from the top.
Release screws (1).

Installation note:
Thinly coat thread of screws (1) with copper paste (CRC).
Attention!
To avoid damaging the threads and prevent exhaust turbocharger
leaks, insert the mounting bolts (1) in 1/2 turns simultaneously to
the stop.
Release the clamp (1) and remove the oil return line from the crankcase.
Release screws (2).
Remove the exhaust turbocharger towards bottom.
Note:
When replacing the exhaust turbocharger:
(figure similar)
Release banjo bolt from oil pressure line (1).
Remove oil pressure line (1).
Pour the additive for the exhaust turbocharger initial filling order number
83 19 2 362 168 into the bore hole for the banjo bolt of the new exhaust
turbocharger.
Crank exhaust turbocharger by hand several times.
Position the oil pressure line (1) on the new exhaust turbocharger.
Tighten the banjo bolt .
Installation note:
- Replace sealing rings.
- The oil pressure line (1) must be installed parallel to the housing
of the exhaust turbocharger.
Installation note:
- Replace all gaskets.
- Clean the sealing surfaces on the exhaust manifold.
11 62 000 Removing and installing, sealing/replacing exhaust manifold
(M47TU / M47T2)
Warning!
Scalding hazard!
Important! Charge air hose screwed into place.

Important!
Charge air hose inserted.
Remove fan cowl.

Release cable and hose on intake pipe.

Release screws.
Detach intake pipe with bypass hose.
Installation:
rings (1).
Release screw (2).
Release screws (3) and remove heat shield.
Note:
Engines with EGR cooler: detach EGR cooler.
Release screw (1).

Slacken screw (2).
Turn fixture in direction of arrow.
Release quick-release coupling on intercooler.
Remove complete charge air tube/hose.
Important!
- Fit charge air hoses without grease and dry.
- Seal turbocharger openings with a cap immediately.
Remove sealing cover (1) from heat shield.

Pull out seal plug.
Installation:
Retaining clip (1) on sealing cover (2) must be inserted at heat
shield.
Installation:
Replaced damaged seal plugs.
Insert three seal plugs (1) from above.
Release screws (1).

Installation:
Apply a thin coat of copper paste (CRC) to screw (1) threads,
Slacken screws (2).
Installation:
Replace all gaskets.
Clean sealing faces on exhaust manifold.
Release all 8 nuts.
Remove exhaust manifold.
Installation:
Replace seals.
Apply a thin coat of copper paste (CRC) to screw threads.
Replace nuts.
11 65 ... Test steps in the event of turbocharger damage
Attention!
The following components must always be checked for foreign
bodies, damage and function before installing the new
turbocharger.
Pressure pipe and hoses
Charge air cooler
Intake plenum
If the oil return line is exchanged, then the connecting pipe to
the oil sump must ALWAYS be cleaned, as this can even
coke!
11 66 000 Removing and installing or replacing vacuum pump (M47)
Caution!

malfunction.
Remove EGR cooler,

refer to 11 71 100.
Disconnect vacuum hose (1) from vacuum pump.

Release screws (2 and 3).
Remove vacuum pump.
Note:
Threads of screws (2) are coated with sealing compound, replace
screws or apply Drei Bond 1209 sealing compound (refer
to BMW Parts Service).
Installation:
Replace O-ring (1) and coat with antiseize agent.
Align driver (2) of vacuum pump to opening in camshaft gear.
Note:
The screw on the camshaft gear has a nozzle for lubricating the
vacuum pump.
11 66 000 Removing and installing or replacing vacuum pump (M47TU /
M47T2 / M57TU / M57T2)
Warning!
Scalding hazard!

On engines with EGR coolers:
Detach pipe between EGR cooler and EGR valve.
On engines without EGR coolers:
Detach EGR pipe.
Release screw.
Detach coupling element of vacuum hose.
Installation:
Replace O-ring during installation.
Release screws.
Remove vacuum pump.
Note:
Screw threads are coated with sealing compound.
Replace screws or apply Drei Bond 1209 sealing compound (refer
to BMW Parts Service).
Installation:
Replace O-ring (1) and apply a thin coat of anti-friction agent.
Align driver (2) of vacuum pump to opening on camshaft gear.
Note:
The screw on the camshaft gear has a nozzle for lubricating the
vacuum pump.
Assemble engine.
Check vacuum system for leaks.
11 71 100 Removing and installing/replacing exhaust gas recirculation
cooler (M47)
Important!

malfunction.
Important!

Remove fan cowl.
E46 only:
Release screws.
Note:
E39 only:
Release screws.
Release screws.
E46 and E39:

Release screws (1) from exhaust gas recirculation cooler.
Installation:
Replace seal.
Detach bracket from exhaust gas recirculation cooler.
Release screws (1) from exhaust gas recirculation cooler.Installation:

Replace seal.

Pull lock and detach coolant hose (2).

Installation:
Release hose clamp (1) and detach coolant hose.
If necessary, remove thermostat for EGR cooler.Installation:

Replace sealing ring between exhaust gas recirculation cooler and
thermostat for exhaust gas recirculation cooler.
cooler (M57 / M47TU)
Important!

malfunction.
Important!
Remove fan cowl.
Note:
For M57 engine.
Release screws (1).

Note:
For M47TU engine.
Release screws.
Drain coolant from radiator. Installation:

Release clamp (1) from exhaust gas recirculation cooler.
Installation:
Release screw (2) of holder for exhaust gas recirculation cooler.
Follow instructions for working on cooling system.

Unlock coolant hose (2) and detach from thermostat.
Release clamp (3) on exhaust gas recirculation cooler (1).
Installation:
Release hose clamp (4).

Detach coolant hose from exhaust gas recirculation cooler (1).
Release screw connections of holder for exhaust gas recirculation
cooler.
Remove exhaust gas recirculation cooler (1).
If necessary, remove thermostat for exhaust gas recirculation

cooler.Installation:
Important!
Exhaust gas recirculation pipe must not be fitted distorted!
Joint all components loose first.
Secure V-band clamp between exhaust gas recirculation cooler and
exhaust gas recirculation pipe.
Then secure the adjoining components to prescribed tightening
torque.
cooler (M47)
Important!

malfunction.
Important!

Remove fan cowl.
E46 only:
Release screws.
Note:
E39 only:
Release screws.
Release screws.
E46 and E39:

Release screws (1) from exhaust gas recirculation cooler.
Installation:
Replace seal.
Release screws (1) from exhaust gas recirculation cooler.Installation:

Replace seal.

Pull lock and detach coolant hose (2).

Installation:
Release hose clamp (1) and detach coolant hose.
If necessary, remove thermostat for EGR cooler.Installation:

11 74 ... Layout of vacuum hoses (M47 / M57TU)
E46 / E39 / E65:

1 Vacuum hose to vacuum tank
1a Vacuum tank
1b Vacuum hose from vacuum tank to pressure converter
1c Pressure converter on turbocharger
1d Vacuum hose from pressure converter to vacuum unit
1e Vacuum unit on turbocharger
2 Vacuum hose to pressure converter
2a Pressure converter for EGR valve
2b Vacuum hose to EGR valve
2c EGR valve
4 Vacuum line
E46 only:
3 Vacuum hose to electropneumatic pressure converter
3a Electropneumatic pressure converter
3b Vacuum hose to vacuum unit on radiator blind
3c Vacuum unit on radiator blind
11 74 ... Layout, vacuum hoses (M47TU)
1 Vacuum line (vacuum pump-brake booster)

2 Vacuum line (vacuum reservoir-suction-air distributor)
3 Vacuum line (vacuum reservoir-EPPT for turbocharger)
4 Vacuum line (EPPT for turbocharger-vacuum unit for turbocharger)
5 Vacuum line (suction-air distributor-EPPT for EGR valve)
6 Vacuum line (suction-air distributor-electric changeover valve for intake manifold)
7 Vacuum line (suction-air distributor-electric changeover valve for radiator shutter)-manual only-
8 Vacuum line (electric changeover valve for intake manifold-vacuum unit for intake manifold)
9 Vacuum line (EPPT for EGR valve-vacuum unit for EGR valve)
10 Vacuum line (electric changeover valve for air exhaust cowl-vacuum unit for radiator shutter)
11 EPPT for exhaust gas recirculation
12 Vacuum unit for intake manifold
13 Electric changeover valve for intake manifold
14 Electric changeover valve for radiator shutter
15 Vacuum unit for EGR valve
16 EPPT for turbocharger
17 Vacuum reservoir
EPPT = Electropneumatic pressure transducer
11 74 505 Replacing pressure transducer for EGR valve (M47TU)
(intake air manifold removed)
Disconnect plug from electropneumatic pressure transducer (EPPT).
Note:
Illustration with engine removed.
Release nut (1).

Slacken nut (2).
Pull out pressure transducer at side.
Detach vacuum hose (3) (from distributor).
Detach vacuum hose (4) (from EGR valve).
Remove pressure converter.
Installation:
11 74 508 Replacing pressure transducer for turbocharger (M47TU)
Turn off ignition.
Caution!

Disconnect plug.
Detach vacuum line to vacuum reservoir (3).
Detach vacuum line to turbocharger pressure unit.
Slacken covered nut (1).
Release nut (2).
Lift out pressure transducer for turbocharger towards top.
Read out fault memory of DDE control unit.
Rectify faults and clear fault memory.
11 . . . . . Equipment recoding special tool number of the transverse
member for fixing the engine in the installation location
Equipment recoding from 00 0 200 to 00 6 0 000
Designation Special tool new Special tool previous

Cross-member, previous --- 00 0 200
Cross-member, new 00 6 000 ---
Mounting bridge 00 6 001 00 0 201
Spindle with hook 00 6 002 00 0 202
Extension 00 6 003 00 0 203
Adapter support 00 6 004 00 0 204
Extension 00 6 005 00 0 205
Chain with hook 00 6 006 00 0 209
Set of supports 00 6 010 00 0 206
Set of supports 00 6 020 00 0 207
Set of supports 00 6 030 00 0 208
Connector 00 6 031 ---
Supports (4 x) 00 6 033 ---
Profile strip 00 6 041 00 0 451
Supports (2 x) 00 6 042 00 0 452
Supports, long (2 x) 00 6 053 ---
Support, long 00 6 060 ---
Supports (2 x) 00 6 070 ---
12 00 ... Instructions for removal and replacement of control units
Important!
Disconnecting the vehicle battery will cancel the fault memories of control units. Consequently, before
disconnecting the car's battery, always interrogate the fault memories. Investigate stored faults and,
once any faults have been remedied, cancel the fault memory.
Control unit plugs should only ever be connected and disconnected while the ignition is turned off.
The removal and installation of components, relays, fuses etc. can cause faults to be stored in fault
memories capable of self diagnosis. Always interrogate the fault memories after completing work on the
electrical system.
Investigate stored faults and, once any faults have been remedied, cancel the fault memory.
If necessary, initialise power window regulator Initialise power window regulator
On replacement of the DME/DDE control unit note the following:
In every case use the diagnosis system to read out the hardware/software version of the corresponding
control unit.
Comply with the diagnosis system instructions for the encoding and programming work operations.
On vehicles with an electronic immobiliser, comply with the diagnosis system instructions.
In every control unit certain mean values are stored that are the basic values. The control unit receives
different input values according to the engine condition. The teachable system compares the input values
against the stored basic values and then forms the associated control commands. The control
commands are forwarded to the corresponding actuators.
When the DME control unit is de-energized for a long period (over one hour), the teachable system then
loses the stored values. When a deleted control unit is returned to service or a new control unit is
installed, the teachable system itself must read in and store the input value of the associated engine as
new basic values.
This process may cause uneven idle and faults in coasting mode after starting. Depending on the engine
characteristics, it may take some time until all values have been compared with the engine condition.
Therefore, comply with the following procedure before replacement or reinstallation of a DME/ DDE control
unit is carried out:
1. If possible, bring the engine up to its operating temperature prior to replacement of the control unit.
2. Change control units and drive the vehicle with changing engine speeds.
Note:
control units.
Attention!
cover the wires.

Attention!
For example:

battery.
Attention!

Note:
bonnet is open.
Prerequisite:
Note:
running.
Trickle charging
Attention!
12 00 ... Notes/information on start assistance (jump starting)
Do not start the engine with help of starting sprays.
Preparation:
Conform with the following when starting the engine with a jump starting cable.
Ensure that the jump starting cable wires are of appropriate cross-section size.
Only use fuse-protected jump starting cables.
Check whether the current-supplying battery has 12 V voltage.
If the engine is started from the battery of another vehicle, ensure that there is no contact between the
bodies of both vehicles.
Important!
Never touch electrically live ignition system components: high voltage - danger of injury!
If the battery in the vehicle supplying power is weak, start the engine of this vehicle and let it run at idling
speed.
Operation:
It is essential to conform to the procedures so as to avoid injury to persons or damage to parts.
Automatic transmission: select drive position ”P”, apply parking brake.
Manual transmission: move gear lever to neutral position, apply parking brake.
Ensure that the jump leads cannot get caught in rotating parts, e.g. fan.
First connect both positive poles of the batteries with one jump starting cable (red).
Use the battery positive terminal in the engine compartment for vehicles with the battery in the luggage
compartment.
Then use the second jump starting cable (black) to connect the negative post of the current-supplying
battery with the earth/ground point (not the negative pole or the body) of the vehicle to be started.
Important!
Do not connect the second jump starting cable (black) with the negative pole of the battery in the
vehicle to be started. Produced gas could be ignited by sparks.
Risk of explosion!
After the engine of the vehicle to be started has fired, first disconnect the jump starting cable between the
negative pole and the earth/ground point. Then remove the starting cable from the positive poles.
61 00 ... Safety information on handling hybrid cars
1. Qualification:
All repair work on high-voltage components may only be performed by specially trained personnel
(qualification: Work on high-voltage inherently save vehicles) must be performed by qualified
technicians. Each hybrid car requires additional vehicle specific training with training achievement
controls.
Required training is offered by the BMW Training Academy.
2. Identification:
Observe warning notices on high-voltage components. When replacing individual high-voltage
components, check if warning stickers are present. Independently attaching warnings is only allowed on
the locations provided for them. Use only approved and appropriately identified original new parts.
3. Rules of conduct/protective measures:
Note operating instructions for handling high-voltage battery units.
Do not under any circumstances touch open high-voltage cables and high-voltage components on
damaged vehicle before shutting down the high-voltage electrical system.
In the event of damage (mechanical, thermal) transition metal oxides, carbon, electrolyte solvents
and their products of decomposition may be released.
Suitable acid-resistant protective clothing/equipment must therefore be used when handling the
vehicle!
Hand protection: Gloves
Eye protection: Safety goggles
Damaged high-voltage battery units must be stored in an acid-resistant pan in a location in the open
that is protected against the weather (sun, rain) and secured against unauthorised access. Do not
inhale escaping gasses.
Prevent escaping substances from entering drains, pits and the sewer system.
Collect any material that is discharged and have it disposed of according to the work instruction,
wear acid-resistant protective clothing when doing so.
Notify the fire brigade if fire breaks out, clear the area immediately and make accident scene safe.
Attempt to extinguish the fire without putting persons in danger (suitable extinguishant: water and
water foam).
A cut 2nd emergency separation point must be repaired with a butt connector.
4. Measures before starting work:
Each job on the vehicle must be assigned by appropriately trained personnel. Before work is
started, this electrician must place the vehicle in the operating condition required to perform the
relevant activity. The qualified personnel's instructions and directions absolutely must be followed.
No work may be carried out without this qualified personnel being consulted first.
It is not permitted to work on the high voltage system or on high voltage components while the
engine is running.
The readiness to drive must be ended before shutting off the voltage of the high-voltage system.
The readiness to drive is ended when the driver is absent only under the following conditions:
1. seat belt buckle unlocked and
2. the driver's door is open and
3. no brake activated and
4. the accelerator pedal is not activated and
5. speed < 3 km/h (2 mph)
Work on live high-voltage components is expressly prohibited. Before each operation on the high-
voltage system, the system must be isolated from the power supply by qualified personnel (high-
voltage safety connector Off) and secured against unauthorised recommissioning (padlock).
After each deactivation of the high-voltage system, it is essential to observe a waiting period of at
least 10 seconds prior to further work.
Before beginning work, it is mandatory to check that the equipment is de-energised and is
protected against being energised again.
Work is only permitted to begin if:
1. Corresponding display in the KOMBI High-voltage system deactivated or
When a high-voltage warning is active (indicator light, Check Control, etc.), it is essential to
determine and eliminate the cause of this warning via the diagnosis system before continuing with
any other work.
If it cannot be definitively established that the equipment is de-energised, work is not permitted
to begin. Danger to life! Before work begins, a qualified electrician (1000 V AC) must verify that the
system is de-energised using appropriate measuring devices and procedures.
=> In this case, Technical Support must be contacted!
Do not perform any work on the vehicle while it is charging. Before starting work, disconnect the
charging cable from the vehicle.
Battery charging may result in heating of the high-voltage battery unit. This heating may lead to
sporadic launches of the electric fan (switch-on request from the electric fan). Therefore, work in the
vicinity of the electric fan during the charging procedure is prohibited. Ensure freedom of movement
of the battery charge lines in the vicinity of the electric fan.
5. Measures during/after activities:
Identifiable mechanical damage to or tampering with high-voltage components must be reported
immediately to the qualified personnel in charge.
When carrying out any work on the high-voltage system, it is prohibited to drive externally all the
drivetrain components (wheels, gearbox, drive shafts, etc.).
E72 only: When the “Power Electronic Box Cover” is removed, the high-voltage system is not
permitted to be activated. The high-voltage service disconnect must only be used when the "Power
Electronics Box Cover" is completely installed.
High-voltage cables (orange coating) and their connectors and stop parts may not be repaired. If
damaged, a cable must always be replaced completely.
When working in the vicinity of high-voltage components (identified accordingly with warning stickers
and orange-coloured coating), protect these components against damage.
The specified work steps in the repair instructions must be adhered to exactly.
High-voltage components and their holders must be screwed/bolted to the defined tightening
torque. Tightening torques and tightening specifications must be observed.
Connecting high-voltage components to body ground is crucial to safety for reasons of
equipotential bonding. For this reason, it is prohibited to operate any high-voltage components
without them being correctly connected to body ground. The measurements (insulation/potential
equalisation measurement) are performed automatically by the vehicle. Manual measurement is not
therefore necessary.
For a correct earthing connection, the retaining elements of high-voltage components must not be
painted. Follow further painting notes.
Removed high-boltage battery units must be stored in a manner that protects them from misuse
and damage.
Damaged or warning stickers that are no longer legible on high-voltage components must always
be replaced.
6. Potential compensation:
Equipotential bonding lines, high-voltage cables and the battery negative lead to the EME are fitted with
safety screws.
Clean contact faces and have then checked by a second person.
Tighten down screws/bolts to specified torque.
Have tightening torque checked by a second person.
Both persons must document that the work has been carried out correctly in the vehicle records.
61 13 ... Unlocking and disconnecting various plug connections in electrical
and hybrid vehicles
Attention!
Observe the following instructions for handling high-voltage plug
connections:
Damaged high-voltage plug connections must be replaced
completely. Repair is not permitted.
Dirt contamination must be removed before opening the plug
connection.
Disconnect the Hirschmann high-voltage connector:

Press the lock (1) on the left and right on the connector in the direction of
the arrow.
Pull off connector (2) in direction of arrow.
Attention!
Connector (2) is difficult to pull off.
In the event of damage to high-voltage connector (2), the complete
high-voltage cable must be replaced!
Connect the Hirschmann high-voltage connectors:

Slide the connector (1) on in the direction of the arrow.
Note:
Connector (2) must lock audibly.
Disconnect the Kostal high-voltage connector:

Unlock and disconnect high-voltage interlock loop (1).
Push the lock (1) fully to the front.
Lift the connector (2) and remove it entirely.
Attention!
Plug connection (3) is difficult to pull off.
The connector (2) must be completely pulled off the opposite
housing in one step. Damage may be caused to contact protection
if connector is only partly pulled off and then closed again!
Check the Kostal high-voltage connector and connection for damage:

Check the touch protection for damage and correct positioning (1).
Warning!
Do not touch unprotected connector (2)!
If the contact protection (1) has been pushed to the bottom (2), the
high-voltage connector must be refitted.
If contact protection (1) remains in bottom position (2) after
reinstallation, the contact protection is faulty and the component
must be replaced!
Check the high-voltage connector (1) for damage.Warning!

In the event of damage to the high-voltage connector (1), the
complete high-voltage cable must be replaced!
Connect the Kostal high-voltage connector:

Connect the connector (2) in one single movement to the counter-
housing.
Push the lock (1) fully to the rear.
Attention!
Plug connection (3) must be correctly locked by lock (2), otherwise
there is a risk of damage.
Connect the connector for the high-voltage interlock.
Three-phase high-voltage connector:

Connect and disconnect the connector straight.
Attention!
The system is designed to only offer limited protection against
damage caused by connectors that are inserted at an angle.
Increased tilted connections will increase the connecting force and
the risk of danger.
Disconnect the high-voltage connector from the high-voltage

connection of the KLE:
Slide lock (1) in direction of arrow up to stop.
Press lock (1).
Open the lock (1) completely and disconnect the connector (2).
Connect the high-voltage connector to the high-voltage connection of

the KLE:
Connect the connector (1) to the limit position and close the lock (2).
Attention!
Lock (2) must snap audibly into place.
The retaining lug of the lock (2) must be positioned completely
under the lock (2).
Slide the lock (1) on to the stop in the direction of the arrow.
High-voltage connector on the high-voltage connection of the high-
voltage battery unit:
Press down unlocking (1) in direction of arrow and pull off connector in
direction of arrow (2).
Attention!
Contact protection is no longer provided in the event of a damaged
connector housing.
In this case, contact technical support.
High-voltage connector on the cell module I01:

Press unlocking device (1) together and pull off connector upwards (2).
Attention!
connector housing.
High-voltage connector on the cell module (cell module connecting

line):
Press unlocking (1) in direction of arrow and pull off connector in direction
of arrow (2).
Attention!
connector housing.
12 14 700 Encoding the control unit (DME/DDE)
Connect diagnosis system.

Switch the ignition on.
Select "encoding" program.
Follow the instructions in the diagnosis system.
Adjust the following control units:
EWS (electronic immobiliser)
DME (Digital Motor Electronics) or
DDE (Digital Diesel Electronics)
Follow Service Information "Diagnosis and Encoding" on the topic of
encoding.
61 35 ... Note on replacing codable/programmable control units
Replacement:
Carry out coding/programming.
Observe following IDC specifications:
Programming
Coding
12 14 705 Programming the control unit (DME/DDE)

Select "Programming".
Follow the instructions in the diagnosis system.
Adjust the following control units:
EWS (electronic immobiliser)
DME (Digital Motor Electronics) or
DDE (Digital Diesel Electronics)
Follow Service Information "Diagnosis and Encoding" on the topic of
programming.
12 14 . . . Relay assignment, engine wiring harness (M47, M57)

Note:
Installation location of relays is in electronics box in direction of
travel, left.
Release screws (1).

Installation:
Tightening torque,
(1) DDE main relay

(2) Wiper relay
Remove glow plug relay,
refer to 12 21 500.
Note:
Read out fault memory of DDE control unit (DDE = Digital Diesel
Electronics).
Rectify faults.
12 21 500 Removing and installing or replacing glow plug relay (M47, M57)
Turn off ignition.

Disconnect battery negative lead from battery and lay to one side.
If malfunctions have occurred on the glow plugs, it is necessary to check
the fuse behind the glovebox.
Installation location of relay for glow plugs:

In electronics box in direction of travel on left.
Release screws (1).
Installation:
Tightening torque,

Unlock glow plug relay (2) with a screwdriver (3) and remove towards top.
Release screw (1) on positive lead.Installation:

Tightening torque,
Relay is activated directly by control unit of Digital Diesel Electronics
(DDE).
Note:
Electronics).
Rectify faults.
12 23 000 Checking all glow plugs (M47, M57)

For the test to be carried out properly, the battery voltage must be
greater than 9 V. Charge battery if necessary.
Release screws (1).

Installation:
Tightening torque,
Disconnect plug connection (1) at glow plug relay (2).
Warning!
Danger of injury and fire!
Do not operate glow plugs when removed!
It is not possible to ensure that heat will dissipate correctly from
glow plugs!
M47:
Connection assignment on plug connection of wiring harness:
Glow plug of cylinder 1 = socket 9
M57:
Glow plug of cylinder 1 = socket 9 (black/green)
Glow plug of cylinder 2 = socket 8 (black/violet)
Glow plug of cylinder 3 = socket 7 (black/yellow)
Glow plug of cylinder 4 = socket 3 (black/red)
Glow plug of cylinder 5 = socket 2 (black/white)
Glow plug of cylinder 6 = socket 1 (black/brown)
Checking with multimeter

Use special tools 61 1 473 and 61 11 475 (test leads).
Connect multimeter between battery positive connection point and plug
connection (1) on wiring harness (refer to connection assignment).
Measure power consumption,
Checking with Beru quick tester

(sourcing reference: BMW Parts Service).
Connect red lead of Beru quick tester to battery positive connection
point.
Connect blue lead of Beru quick tester to ground.
Connect black lead of Beru quick tester to special tool 61 1 473 (test
lead). Connect special tool 61 1 473 (test lead) to plug connection (1) on
wiring harness.
The red lamp lighting up indicates that the Beru quick tester is ready.
To start check, press start button on Beru quick tester.

The green bulb is lit during the check.
The check takes approx. 12 seconds.
Indication Result
Needle in green zone Glow plug O.K.
Needle in red zone Glow plug faulty
Red lamp lit Test completed
Tester is now ready to test the next glow plug.
Notes on troubleshooting:
If a glow plug is shown to be faulty during the test, it is absolutely
essential to check the following components:
Supply lead from relay to glow plug

Plug connection on glow plug
Activation of relay for glow plugs
100 A fuse behind glovebox
Refer here also to the Electrical Troubleshooting Manual, Chapter 1360
Digital Diesel Electronics. Add final details to vehicle.
Note:
Electronics).
Rectify faults.
12 23 505 Replacing all glow plugs (M47)
Note:
If malfunctions have occurred on the glow plugs, it is necessary to
check the fuse behind the glovebox.
For further information on troubleshooting, refer to Diagnosis and
Information System (DIS).
Turn off ignition.

refer to 11 61 050.
Press together locks on plugs and detach plugs from glow plugs.
Remove cable channel from retainer and lay to one side.
Unscrew glow plugs with special tool 11 6 050.

Note:
If necessary, drill out special tool 11 6 050 with a 9.5 mm drill approx.
20 mm deep.
Installation:
Tightening torque,
Read out fault memory of DDE control unit, check stored fault messages,
rectify faults, clear fault memory.
12 23 505 Replacing all glow plugs (M57 / M57TU / M47TU / M47T2 / M57T2)

11 6 050
12 2 300
Note:
Electronics).
If malfunctions occur at the glow elements, it is absolutely essential to
check the safety fuses behind the glove box.
For further troubleshooting information refer to the BMW diagnosis
system.
Note:
It is recommended to warm the engine up to operating temperature for
easy removal of glow elements. In addition, spray glow element with
Disassembly agent 5.1 and let it take effect for approx. 2 minutes.
Removing glow elements from a cold engine may cause damage to the
thread in the cylinder head.
Attention!
Risk of burning! The use of gloves is mandatory!

Disconnect battery earth lead.
Release connector (1) with special tool 12 2 300 and remove.

Release glow elements (1) with special tool 11 6 050 .
Note:
If applicable, drill out the special tool 11 6 050 with a twist drill ∅ 9.5 mm
approximately 20 mm deep.
Installation note:
Different glow elements in M47 and M47TU engines!
M47 glow elements (1) without designation groove.
M47TU rapid start glow elements (2) with designation groove and silver
surface.
Note:
Delete the fault memory.
12 31 009 Checking alternator and regulator switch
Test requirements:
Correct connections on charged battery
Correct connections on alternator and starter motor
Good ground connection between engine and body
Tightened drive belt
Connect DIS Tester.

Measurement
Checking alternator
If charge indicator lamp is permanently lit:

Remove voltage regulator and check carbon brushes, replace if
necessary.
Replace alternator regulator switch.
Note:
Minimum length of carbon brushes ”A” = 5 mm.
If charge indicator lamp goes out while engine is running:

Check control voltage.
Regulator switch must be replaced if control voltage is not achieved.
Replace alternator regulator switch.
From E46/E39 with multifunction regulator.

Recognizable by plug connection on regulator.
Connect DIS Tester.
Function selection
Complete vehicle
Drive
Voltage and current regulation
Voltage and current generation
Work through test modules
Oscillogram for a fault-free alternator:
Oscillogram for a faulty alternator:

One phase interrupted.
Repair/exchange alternator.
Interturn fault.
Open circuit in negative diode.

Short circuit in positive diode.
Open circuit in positive diode.

Open circuit in exciter diode.

12 31 020 Removing and installing/replacing alternator (M47 / M47TU)
Read fault memory.

Battery negative lead: Release battery terminal clip and remove and
cover battery negative lead.
Caution!

malfunction.
Caution!
E46 manual:
E39 / E46 automatic:
Replace fan cowl.
Disconnect battery negative lead (1) to alternator at solenoid switch of

starter motor.
Disconnect alternator plug connections.
Slacken screw connection on belt pulley of power steering pump.
Remove alternator drive belt.
Release screw (1).

Remove idler pulley for drive belt.
Release screws and remove belt pulley on power steering pump.
Release screw connection (1) on alternator and remove alternator.

Remove protective cap (1).
Release nut and disconnect battery positive lead (2).
As required, remove battery positive lead to terminal and to flow heater.
Note:
Read fault memory.
Rectify faults.
12 31 230 Removing and installing/replacing alternator mounting block (M57
/ M47TU)
Remove and install alternator.
Note:
For M57
Release screws (1).

Remove alternator mounting blockÂ (2).
Note:
For M47TU
Alternator mounting block is a component part of the engine support arm.

Release screws.
Remove support arm with glow control unit.
Note:
Refer also to Removing left engine support arm.
12 32 501 Replacing regulator switch for alternator (M47TU)
Instructions for disconnecting and connecting battery.

Disconnect battery negative lead on battery side and cover.
Alternator removed.
Remove and install alternator.
Valeo alternator:
The cover is engaged at three points (1).
Carefully insert a screwdriver between cover and alternator.
Lift out cover.
Pull off cover cap (2).

Release nuts (arrow).
If necessary, remove sealing compound in area (1).
Release contact screws underneath.
Remove regulator.
Check contact faces (1) of slip rings for wear and recondition if
necessary.
Installation:
Fit new regulator with attached mounting sleeve (1).
Tighten retaining nuts (2).
Tighten contact screws (3).
Pull off mounting sleeve (1) and replace with cover cap (4).
Fit cover and lock in place.
12 32 501 Replacing voltage regulator (Valeo/Bosch)
Read General Information in MG12.

Read fault memory.
Disconnect battery ground wire.
Remove alternator.
Valeo alternator:
Release screws on cover.
Release screws.
Remove regulator switch.
Check contact surfaces of collector rings for wear and recondition if

necessary.
Installation:
Install regulator switch with assembly cap.
Initially tighten nuts of regulator switch.
Installation:
Remove assembly cap (1).
Installation:
Fit supplied cover cap (2).
Tighten down nuts and ground screw of regulator switch.

Bosch alternator:
Release screws on cover.
Release screws.
Remove regulator switch.
Check contact surfaces of collector rings for wear and recondition if
necessary.
12 41 020 Removing and installing or replacing starter (M47)
Read fault memory. Switch off ignition.

Disconnect battery negative lead.

E46 only:
Release screw (1) and remove side sound insulation (2).
E46 and E39:

Disconnect positive leads (1) and both control leads (2 and 3) from
starter.
Installation:
Tightening torque,
Note:
Illustration shows starter screw connection on removed engine.
Release screw (1) on sound insulation.

Release screws (2) and swivel out starter past engine support.
Installation:
Tightening torque,
Pull out starter motor (3) with end opposite drive pinion between oil
dipstick (1) and stabilizer (2).
Solenoid switch (4) must be on top side of starter motor here.
Installation:
Do not squeeze sound insulation (1) when installing starter.
12 41 020 Removing and installing/replacing starter motor (M47TU)
Note: Read fault memory. Switch off ignition.

Remove underbody protection at front and rear.
Drain engine oil.
Release screw (1).

Remove side acoustic insulation (2).

Release screws.
Unfasten screws.
Remove lower section of microfilter housing.
Loosen screws (1).

Remove shield.
Remove oil dipstick.

Release oil dipstick guide tube on manifold.
Remove guide tube.
Release plug to glow control unit.
Remove glow control unit.
Remove holder for glow control unit (two screws on right side).
Disconnect positive lead (1) and both control lines (2 and 3) on starter.
Installation:
Detach positive lead (2) of auxiliary heater from solenoid switch on

starter motor.
Detach battery positive lead (3) from solenoid switch on starter motor.
Note:
Illustration shows starter motor on removed engine.
Loosen screws (2).
(For accessibility reasons, use extensions and joint.)
Note:
Withdraw starter motor (1) from transmission flange and tilt out past
engine carrier.Installation:
12 41 041 Replacing the engagement solenoid switch
Necessary preliminary work:

Remove starter motor.
Slacken nut (1).

Remove the cable shoe (2).
Attention!
Do not twist the cable shoe (2) when tightening, risk of shorting to
starter motor housing.
Release screws (1).
Remove the solenoid switch (1) and the spring (2).

Detach the bolt (3).
Installation note:
Check the bolt (3) for wear and grease the bolt.
12 42 500 Replacing battery positive lead (M47TU)
Read fault memory. Switch off ignition.

Observe safety instructions for handling vehicle battery.
Remove front underbody protection.

Open cable duct on lower section of microfilter housing (2).

Feed out cable.
Feed battery positive lead out of cable duct.
Fold back protective cap (1).

Release nut (2).
Installation:
Disconnect battery positive lead (3) from connection point.

Detach rubber grommet of positive lead from engine acoustic insulation.
Release positive lead from retaining clip.

Release positive leads from terminal to alternator (1) and from alternator
to starter motor (2).
Note:
Line (3) leads to auxiliary heater.
Installation:
Disconnect battery negative lead (1) to alternator at solenoid switch of
starter motor.
Note:
Rectify faults.
Then clear fault memory.
12 42 540 Replacing safety battery terminal (SBK)
Caution!
Observe safety regulations.
Investigate cause of triggering of safety battery terminal.
To do so, read out fault memory of airbag control unit. Note fault
messages stored in memory. Rectify faults. Then clear fault memory.
Use of safety battery terminal:

From model year 1998 in Series E38, E39, E46
From 4/99 in E36/Z3
in each of following new Series
The different models have different installation locations:
Battery in engine compartment

Safety battery terminal is replaced with cable up to battery positive
support point.
Safety battery terminal is omitted as from 03/2002 from all E46 LHD
models with 4-cylinder engines.
Battery in luggage compartment behind side trim panel

Remove side trim panel.
Release front side trim panel partly and fold forward.

Battery in luggage compartment under floor trim panel
Fold back floor trim panel (1).
Lift cover (2) on battery negative lead.
Disconnect and cover battery negative lead (3).
Release nuts (4).
Remove battery cover.
Battery in luggage compartment under spare wheel

Remove spare wheel.
Release screws.
Caution!
Do not kink air pipes.
Set air supply system (1) to one side.

Disconnect supply cable (1) for vehicle electrical system.Installation:

Remove faulty fuses and carry out troubleshooting.
Caution!
Pay attention to interface.
The repair cable is always a standard length.
The heavy-current connector of the repair cable has a larger
diameter than the battery positive lead.
In some Series (e.g. E46 touring), the heavy-current connector of
the repair cable can lead to installation problems.
This is the case when the interface is in the area of the close-fitting
trim panels.
Find matching interface (e.g. approx. 10 cm behind rear seat
backrest in E46 touring).
Lay repair cable parallel to battery positive lead.
Mark interface of battery positive lead at end of repair cable.
Release cable ties (1).

Caution!
Do not use bolt cutters or similar tools to cut through the cable.
A cable end that has been squashed flat will no longer fit into the
clamping sleeve.
Saw through battery positive cable at marked point with an iron saw.
Strip insulation - length (A) - from cable end.

Distance (A) = 15 mm.
Push heavy-current connector (1) over stripped cable end and screw
into position.
Push shrink-fit hose (3) over repair cable.

Screw threaded sleeve (1) of repair cable (2) to heavy-current
connector.
Push shrink-fit hose (1) over connecting point and shrink on with a hot-air
blower (2).
Note:
Heat up shrink-fit hose until it has settled completely around the
connection point.
When laying the repaired battery positive cable, observe the following:
The shrink-fit hose must not be scuffed during any movement.
The repair cable must not cause any disturbing noises during driving
operation.
Note:
Offsetting cutting line by approx. 10 cm produces excess length of
battery positive lead (1).
Lay battery positive lead (1) without kinks or abrasions.
(Shown on E46 touring.)
12 51 001 Replacing wiring harness section for engine (M47)
Read fault memory of DDE control unit. Switch off ignition.

refer to general information in MG 12.
refer to 11 61 050.
Disconnect plug connections (1) on pressure converter for variable

turbine geometry and (2) on air-mass flow sensor.
Disconnect plug connections (1) for needle motion sensor on cable

channel and (2) on coolant temperature sensor.
Press together locks of connectors (1) on glow plugs and disconnect all
connectors.
Disconnect plug connection (1) at speed sensor.
Disconnect plug connection (1) on pressure converter for EGR valve.
Disconnect plug connection (1) on control valve for radiator blind.
Force engine wiring harness to one side and expose injection pump.
Disconnect plug connection (1) on injection pump.
Disconnect plug connection (1) on oil pressure switch (2).
Installation:
Tightening torque,
Disconnect plug connection on alternator.
Disconnect plug connection (1) on oil level switch (2) and release cable
fastening.
Detach cable from transmission.
For E46 only:

Release screws (1) and remove cover from electronics box.
Disconnect plug connection (1) on relay for glow plugs (2).
Detach DDE main relay (1) with socket from carrier.

Wiper relay (2) remains fitted.
Disconnect all plug connections on DDE control module (Digital Diesel
Electronics).
Detach engine fuses (1) with socket from carrier.

Disconnect plug connections (2).
Disconnect ground cable from support point (1).

Replace wiring harness section for engine.
For E39 only:
Release screws (1).
Tightening torque,
Remove electronics box cover (2).
Disconnect plug (1) on DDE control unit.

Separate plugs (2 and 3).
Disconnect plug (4) on preheating relay.
Remove wiring harness section (5) from electronics box.
12 51 001 Replacing wiring harness section for engine (M47TU)
Read out fault memory of DDE control unit. Switch off ignition.
Refer to general information in MG 12.
Disconnect plug connections on pressure transducer for variable turbine

geometry (EPPT for VNT).
Disconnect plug connection on A/C compressor.
Disconnect plug connections for air-mass flow sensor (1), camshaft

sensor (2), rail pressure sensor (3) and injectors (4).
Disconnect plug connection for charge air temperature sensor.

Disconnect plug connection for delivery control valve (1).
Disconnect plug connection for EPPT actuator, exhaust gas recirculation

(EGR).
Disconnect plug connection for oil pressure switch.
Disconnect plug connections for pressure control valve (1), glow

elements
(2) and coolant temperature sensor.
Press locks together of plugs (1) for glow elements.
Disconnect plugs.
Disconnect plug connection on crankshaft position sensor (2).

Disconnect plug connections on control unit for glow elements (1).
Note:
Connection from control unit to starter motor can remain.
Unfasten screws.
Remove cable channel.
Installation:
Disconnect plug connection on alternator.

Disconnect plug connection (1) on oil level switch (2).
Release cable retaining points.
Detach cable from transmission.
Note:
Release screws (1).

Detach seal (1).

Detach bracket (2).
Detach profile seals (3) with wiring harnesses.
Release panel (4).
Detach profile seal (5) with wiring harness.
Disconnect plug connection on DDE 5 control unit (1).

Disconnect plug connections on transmission control unit: module 4 (2)
and module 2 (6).
Detach relay for reversing light (RFL) (3).
Detach relay for ”Digital Diesel Electronics” (DDE) (4).
Detach engine fuse with socket (5) from equipment carrier.
Release engine plugs (7, 8).
Disconnect ground cable from terminal (1).
Release rubber grommets affected.
Remove wiring harness section for engine.
12 51 200 Replacing wiring harness section for injectors (M47TU)

Remove microfilter.
cable(s).
heater bulkhead underneath.

Unfasten screws.
Unfasten screws.
Release nut.
Disconnect cable from terminal.
Open battery terminal housing.
Unfasten screws.
Detach injector plug.
Lay injector wiring to one side.
Detach sealing strip (1).

Pull out profile seal (2).
Installation:
To prevent leaks, you must install profile seals correctly.
Release screws (1).
Installation:
Disconnect plug (1) on DDE control unit.

Pull profile seal of wiring harness out of electronics box.
Installation:
To prevent leaks, you must install profile seals correctly.
Remove wiring harness section for injectors.
Pull out lock.

Press out the two plugs belonging to the injector wiring harness.
Note:
Electronics).
Rectify faults.
1. Qualification:
controls.
2. Identification:
vehicle!
water foam).
engine is running.
any other work.
and damage.
be replaced.
safety screws.
12 61 285 Removing and installing/replacing oil level sensor

Switch off ignition
Unfasten oil filter cap to enable engine oil in filter to flow back
into the oil sump
Remove underbody panelling
If necessary, remove reinforcing plate
Drain off engine oil

Unscrew nuts (2).
Remove oil level sensor (3).
Installation note:
Clean sealing surface on oil sump.
Replace seal on oil level sensor.
Installation note:
Top up engine oil.
Screw on oil filter cover tightly.
12 61 280 Removing and installing/replacing oil pressure switch (M47)
Caution!

malfunction.
Note:
To avoid an excessive discharge of oil when the oil pressure switch
is removed, it is necessary to drain the main flow oil filter.
Caution!
socket only.
When the main flow oil-filter cover is released, the oil flows from the
oil-filter housing back into the sump.
Release main flow oil-filter cover and remove towards top.
Installation:
Fit and tighten down main flow oil-filter cover.

Tightening Torque,
Unfasten screws.
Note:
Screw (1) is not visible in this view.
Caution!
A small amount of engine oil will be discharged when the oil
pressure switch is removed. Have a cleaning cloth ready.
Disconnect plug connection (1) and remove oil pressure switch

(2).Installation:
Tightening Torque,

13 31 028 Checking fuel delivery pressure (M47)
The fuel pump relay is operated by the DDE control unit. If problems
arise when operating the relay, also read out the fault memory of the
DDE control unit. For additional troubleshooting, refer to BMW DIS
(section on operating components).
Caution!

malfunction.
Withdraw fuel filter (1).
Caution!
Catch emerging fuel in a suitable container and dispose of fuel.
Press together locks of fuel feed line (coming from injection pump) and
detach connecting piece (1) from fuel filter (2).
Connect special tool 13 5 290 and 13 5 272 and attach to pressure

sensor (up to 3.5 bar) of DIS tester (2).
Connect special tool 13 5 290 to connecting piece of fuel feed line
(coming from injection pump) and to fuel filter (1).
To check fuel pressure, slide fuel filter (1) back into bracket so that it is
vertical.
Start engine and read off specified value at idle speed.
Specified value for fuel delivery pressure from fuel pump, or to injection
pump,
Inspection procedure for all models:
Increase engine speed to 4000 rpm and observe pressure at tester.
The delivery pressure must drop considerably at higher engine speed
due to the suction effect of the injection pump.
Brief vacuum is permitted.
Caution!
When removing pipe adapter, catch fuel in a suitable container.
13 31 028 Checking fuel feed pressure (M47TU)

13 5 270

Switch off ignition
Recycling:
Catch and dispose of escaping fuel.
Release screws (1).

Remove trim.
Release screws (2) or quick-connect couplings.
Remove trim.
Connect special tool 13 5 270 with quick-connect coupling to pressure

sensor (2) of DIS (Diagnosis and Information System).Note:
When disconnecting fuel line, catch and dispose of escaping fuel.
Unclip fuel feed line (1).

Unlock and disconnect fuel feed line (1).
Bridge joint with special tool 13 5 270 .
Start engine and run at idling speed.
Check fuel feed pressure.
13 31 025 Checking fuel return pressure (M47TU)

13 5 270
Turn off ignition.
Caution!
malfunction.
Recycling:
Loosen screws (1).

Remove panel.
Release screws (2).
Remove trim.
Release nuts (1).

Remove protective plate.
Connect special tool 13 5 270 with quick-connect coupling to pressure
sensor (2) of DIS (Diagnosis and Information System).Caution!
Detach fuel return line (2).

Close joint with special tool 13 5 270 .
Start engine and run at idling speed.
Caution!
Note:
Fuel return pressure.
13 53 ... Layout of common rail system (M47TU / M47TU2)
1 Pressure line, cylinders 1 and 3 5 Pressure sensor

2 Pressure line, cylinders 2 and 4 6 Pump line
3 Injectors 7 Rubber mount
4 High-pressure accumulator 8 H.P. pump
9 Pressure regulator
13 32 040 Removing and installing/replacing fuel cooler (M47)
Turn off ignition.
Caution!

malfunction.
Caution!
Catch escaping fuel.
Release screws (1) on air duct.

Tightening torque,
Release hose clamps (2 and 3) on fuel feed and fuel return and
disconnect hoses.
Installation:
Always replace hose clamps.
Release screws (4) (3 screws) and remove fuel cooler.

Drain and dispose of fuel from fuel cooler.
Installation:
To vent fuel filter:
Turn on ignition and leave on for approx. 1 minute. In this period of
time, the fuel pre-supply pump is activated and the fuel cooler is
filled with fuel and vented.
13 32 051 Renewing fuel preheating
Removal of the filter unit is described in

Changing fuel filter.
Installation note N47:

Venting fuel system:
Bleed fuel system using BMW diagnosis system.
13 32 051 Replacing fuel filter (M47)
Turn off ignition.
Caution!

malfunction.
Screw on cap (1).

Remove fuel filter.
Tightening torque,
Installation:
Check fuel filter housing for contamination. If necessary, clean and
determine cause of contamination.
Before installing new fuel filter, draw off and dispose of fuel from
housing.
Installation:
time, the fuel pre-supply pump is activated and the fuel filter is filled
with fuel and vented.
13 32 051 Replacing fuel filter (M47TU / M57TU)
Important!
Recycling:

Unfasten hose clips.

Remove hoses.
Remove fuel filter.
Detach rubber mount.
Installation:
Check rubber mount and replace if necessary.
Check hose clamps, replacing if necessary.
Note:
M57TU AWD
Unlock plug connections (1) and disconnect.

Release hose clamps (2) and detach fuel hoses from fuel filter.
Remove fuel filter with rubber mount.
Detach rubber mount.
Release clamp (3) and remove electric preheater.
Installation:
Check rubber mount and replace if necessary.
Check hose clamps, replacing if necessary.
Installation:
To vent fuel system:
time, the fuel pre-supply pump is activated and the fuel line to the
H.P. pump vented.
13 32 061 Replacing fuel filter unit (M47)
Turn off ignition.
Caution!

malfunction.
Screw on cap (1).

Remove fuel filter.
Tightening torque,
Draw off and dispose of fuel from fuel filter housing.
Caution!
Catch escaping fuel.
Press clamps and disconnect lines (1 to 4). Catch escaping fuel.

1. Fuel feed from fuel tank
2. Supply line to fuel cooler
3. Fuel return from injection pump
4. Fuel feed to injection pump
Installation:
Check sealing rings, replace if necessary.
To simplify assembly operation, coat seals with acid-free grease.
Remove fuel filter unit (1) towards top from retainer (2).
Drain contents of filter into a suitable container and dispose of contents.
Installation:
time, the fuel pre-supply pump is activated and the fuel filter is filled
with fuel and vented.
13 32 070 Replacing preheating valve (M47TU / M57TU)
Important!Switch off ignition.
Important!
malfunction.
Recycling:

Remove splash guard.
Release clamps (1).

Release lockÂ (2) and disconnect fuel lines.
Detach valve holder.
Remove preheating valve.
Installation:
time, the fuel pre-supply pump is activated and the fuel cooler is
filled with fuel and vented.
13 51 542 Checking high pressure pump (M47TU / M57TU)

12 7 420
13 5 450
13 5 455
13 5 456
13 5 457
61 4 390

Remove intake plenum (M47TU)
Remove intake plenum (M57TU)
Important!
Before the engine start, make sure that no foreign bodies get into
the combustion chamber.
Risk of damage.
Protect alternator against dirt contamination.
Cover alternator with suitable auxiliary materials.
Risk of damage.
Protect high pressure pump against contamination. Replace high
pressure line.
Recycling:
Release union nut (1) (high pressure line).

Installation note:
Replace high pressure line (2).
Connect special tool 13 5 450 to high pressure pump.

Important!
Use special tool 13 5 455 a maximum of 3 times.
Disconnect plug connection of pressure control valve (3) and rail

pressure sensor (5). Connect special tools13 5 456 and 13 5 457
between special tool 13 5 450 and engine wiring harness.
Connect return line (4).
Note:
M47TU only.
Connect special tool 12 7 420 and 61 4 390 to control unit connector
(X2412).
Bridge pin 32 (ground) to pin 2.
Note:
M47TU only.
Disconnect plug connection (1) at high pressure pump (2).
Note:
DDE software ≤V42 diagnosis not possible.
DDE software V42 or ≥ V42 (reprogram if required).
Diagnosis and information system tester procedure.

-
-
-
-
-
-
Start engine and read off pressure. Refer to Technical Data.
13 51 040 Checking injection pump measured value (M47)
Coolant temperature > 20° C.

Connect DIS or MoDiC to diagnosis socket.
Select diagnostic program of DDE control unit.
Caution!

malfunction.

refer to 11 61 050.
refer to 17 11 020.
Read off setting value in area (1) on injection pump.Note:

The setting value is stamped on the nameplate (e.g. 0.86). If
necessary, detach fuel line to obtain reading.
Remove plug (1) of alignment bore from crankcase.

Open oil filler neck.
Crank engine in direction of rotation until cast lug (1) on inlet camshaft
points upwards.
Note:
Cast lug (1) on inlet camshaft points upwards at firing TDC, cylinder
1.
Caution!
Do not damage hexagon socket of plug for static basic adjustment.
Unscrew plug for static basic adjustment (1).Note:

Plug is located approx. 30 mm behind blocking screw.
Installation:
Replace sealing ring without fail.
Tightening torque,
Install special tool 13 5 200.

Secure special tool 00 2 510 (dial gauge) under preload.
Pull out special tool 11 2 300.
Rotate crankshaft 90° against direction of engine rotation. Set scale of
dial gauge to zero.
Lay special tool 11 2 300 (plug mandrel) parallel to speed sensor (1) on
reinforcing rib of engine and force it approx. 1...2 cm into support in
crankcase.Note:
To provide more space to work in, remove injection lines for
cylinders 3 and 4,
refer to 13 53 200.
Rotate crankshaft in direction of engine rotation until special tool 11 2 300
(plug mandrel) audibly snaps into place.Note:
1.
Read dial gauge.Evaluation of measurement:

The value read off may deviate from the value stamped on the
injection pump by max. ± 0.1 mm.
If deviations are greater than ± 0.1 mm, statically adjust injection
pump,
refer to 13 51 005.
13 51 522 Fuel metering unit (M47TU/M47T2 / M57TU, M57T2)

Remove air intake manifold (M47TU, M47T2 only).
Important!
Adhere to the utmost cleanliness.
Dirt particles must not be allowed to get into the high-pressure
pump.
Disconnect plug connection (1) on metering unit.

Release screws (2).
Remove metering unit (1) in direction of arrow.
Assemble engine.
Check fuel system for leaks.
13 51 004 Removing and installing/replacing high-pressure pump (M47TU,
M47T2)

13 5 020
13 5 190
13 5 191
13 5 192
Important!
malfunction.
After disconnecting the injection line, it is absolutely essential to seal the

high-pressure pump and the high-pressure accumulator with protective
caps.
The position of the H.P. pump to the valve gear does not affect its
operation.
Recycling:

Switch off ignition
Layout of common rail system
Remove intake air manifold
E46, E87 only:
Remove fan cowl
Disconnect plug (1) from pressure regulator of H.P. pump.
Release clamp (2).
Detach fuel feed line from H.P. pump.
Installation:
Replace clamp (2).
Release fuel return line (3) on H.P. pump. (Banjo bolt).

Installation:
Replace seal of banjo bolt.
Release union nut (4) on H.P. pump and union nut on H.P. accumulator
with special tool 13 5 020 .
Remove H.P. line.
Note installation position of rubber mount on H.P. line.
Release nuts (1) on H.P. pump.
Remove alternator ribbed V-belt from tensioning roller.

Open plug (1).
Installation:
Release nut (1) on sprocket wheel of H.P. pump.

Screw special tool 13 5 192 into timing case cover at front.
Screw special tool 13 5 191 without forcing screw (1) into sprocket wheel
of H.P. pump.
Then insert forcing screw (1) until contact is made.
Tighten forcing screw (1) until H.P. pump is released from sprocket wheel.
Remove H.P. pump.
Important!
Special tool 13 5 190 must remain in the vehicle to secure the
sprocket wheel and must not be removed under any circumstances!
Remove jack screw (1) to install high-pressure pump.
Installation:
Replace gasket (1).
Note position of seal (1).
Sealing faces must be dry and grease-free.
Installation:
Turn on ignition and leave on for approx. 1 minute. In this period of time,
the fuel pre-supply pump is activated and the fuel system is filled with fuel
and vented.
13 51 000 Removing and installing/replacing injection pump (M47)
Connect DIS or MoDiC to the diagnostic socket. Select diagnostic

program for DDE control unit.
Important!

malfunction.

refer to General Information HG12.
Disconnect and cover battery earth lead.
Remove engine guard.
Remove radiator shutter,
refer to 17 11 020.
Disconnect plug connections on pressure converter for variable turbine

geometry (1) and on air mass meter (2).
Disconnect plug connections for needle movement sensor (1) on cable

channel and on coolant temperature sensor (2).
Press locks of connectors together and detach connectors from glow
elements.
Disconnect plug connection on speed sensor (1).
Disconnect plug connection on pressure converter for EGR valve (1).
Disconnect plug connection on switching valve for radiator shutter (1).

Press engine wiring harness to one side and expose injection pump.
Disconnect plug connection on injection pump (1).
Remove all injection lines,

refer to 13 53 200.
Important!
Releasing the screw (1) also releases the holder for the oil dipstick
guide tube. This must not be pulled upwards.
Oil leakage from the oil sump!
Release screw (1) and remove switching valve for radiator shutter with
holder (2).
Detach vacuum hose (1) to EGR valve and (2) to distributor in hose to
vacuum pump on pressure converter for EGR valve.
Release screws (3) and remove pressure converter for EGR valve.
Release screws (1) on injection pump.

Release screws (2) on engine block and remove injection pump
support (3).
Detach leakage oil hose (1).
Release banjo bolts (2). Remove fuel lines.
Installation note:
Replace leakage oil hose.
Replace seals.
Tightening torque,
refer to Technical Data 13 51 10AZ .
See technical data 13 51 11AZ.
Release screw plug.Installation note:

Check O-ring, replace if necessary.
Tightening torque,
Removal:
Subsequent removal of the injection pump is described separately from
installation.
Assembly sequence for removal and installation is different from this
point.
Release central nut (21 AF) on injection pump shaft.

Grip the crankshaft at the front central bolt in the process.
Tighten down central nut again to approx. 30 Nm.
Pull seal plug (1) of dowel hole out of crankcase.

Crank engine in direction of rotation until the cast iron lug (1) on the
intake camshaft points upwards.
Note:
Cast iron lug (1) on intake camshaft points upwards with cylinder
no. 1 at firing TDC.
Lay special tool 11 2 300 (alignment pin) parallel to speed sensor (1) on
engine reinforcing rib and allow to engage audibly at cylinder no. 1 firing
TDC.
Important!
The shaft may rotate if the injection pump shaft is not blocked by
the blocking screw.
This will cause the reference for installing the pump to be lost and
the pump will have to be statically readjusted,
refer to 13 51 005.
Release blocking screw (1) on injection pump.

Remove spacer (2) and tighten down blocking screw (1). This blocks the
pump shaft.
Tightening torque,
Release central nut on injection pump shaft and remove.
Screw in special tool 13 5 190 without forcing screw and tighten down.
Release nuts (1) and (2, concealed) on injection pump bearing support.
Insert forcing screw (1) into special tool 13 5 190 and detach sprocket
from injection pump shaft.
Detach injection pump from mounting flange and remove.
Important!
Leave special tool 13 5 190 screwed in until the injection pump is
reinstalled, otherwise the sprocket will fall down and the engine will
have to be disassembled.
Remove forcing screw only.
Installation:
Installation of the injection pump is described separately from removal.
The assembly sequence differs between removal and installation.
Make sure the engine is at cylinder no. 1 firing TDC and aligned at the
crankcase with special tool 11 2 300 (alignment pin).
Carry out visual inspection of installation position:

The groove (1) in the injection pump shaft must be flush with the fuel
injection line connection (2) for cylinder no. 1.
Read off and note down adjustment value on injection pump.Note:
The adjustment value is stamped on the type plate (e.g. 0.86).
Important!
Do not release blocking of injection pump shaft.
Replace gasket (1).
Insert injection pump with blocked drive shaft into bore hole in engine
mounting flange.
Tighten down nuts (1) and (2, concealed) on injection pump bearing
support.
Install injection pump support (3) and tighten down screws (1) and (2).
Unscrew special tool 13 5 190.
Fit central nut and tighten down to approx. 15 Nm (initial torque).
Release blocking screw (1) on injection pump.

Insert spacer (2) and tighten down blocking screw.
Note:
Spacer (2) is supplied loose with new or exchanged injection
pumps.
Tightening torque,
Pull out special tool 11 2 300 (alignment pin).

Tighten down central nut on injection pump.
Grip the crankshaft at the front central bolt in the process.
Tightening torque,

Crank engine slowly in direction of rotation until the cast iron lug (1) on
the intake camshaft points upwards.
Note:
Remove screw plug (1) so that the adapter for the dial gauge can be
fitted.
This graphic shows the measuring principle for the VP 44:

1 Injection pump shaft with milling
2 Injection pump housing
The gauge tip of the dial gauge measures on a ramp of a curve contour
and thus responds with great precision to a change in the setting in
relation to the crankshaft.
The gauge tip contour and the curve contour are matched to each other;
only the specified special tool may be used!
Using a different or damaged gauge tip will result in misadjustments of the
injection pump!
Important!
Check the gauge tip of the special tool before installing in the
injection pump.
The gauge tip (2) of special tool 13 5 200 must be clean and without
burrs so that the injection pump is not damaged and the
measurement result is not distorted.
1 Injection pump shaft (arrow denotes direction of rotation of injection

pump shaft)
2 Gauge tip of special tool 13 5 200. Dimension ”X” corresponds to the
adjustment value stamped on the injection pump.
Mounting dial gauge:

1 Screw in special tool 13 5 200.
2 Secure special tool 00 2 510 (dial gauge) under preload.
3 Rotate crankshaft 90° against direction of engine rotation.
4 Set dial gauge scale to zero.
Lay special tool 11 2 300 (alignment pin) parallel to speed sensor (1) on
engine reinforcing rib, and press approx. 1...2 cm into mounting in
crankcase and hold down.

(alignment pin) audibly engages.Note:
Read the dial gauge.Evaluation of measurement:

The read-off value may deviate from the value stamped on the
injection pump by max. ± 0.1 mm.
The injection pump must be statically adjusted if deviations are
greater than ± 0.1 mm,
refer to 13 51 005.
Remove special tool 13 5 200 together with special tool 00 2 510 (dial
gauge).
Note:
Replace sealing ring without fail.
Tighten down screw plug (1).

Tightening torque,
Assemble engine.Note:
Leave ignition switched on for at least 1 minute. The fuel pre-supply
pump is activated by the DDE control unit. The fuel system thus
vents itself.
A longer starting time is normal after the injection pump is removed.
Crank engine with starter.
Note:
If the injection pump has been replaced, ”Adjustment pump
characteristic map” must be performed:
1. Connect DIS Tester

2. Identify vehicle
3. Select ”Function selection”
4. Select ”Service functions”
5. Select "Digital Diesel Electronics (DDE)"
6. Select ”Adjustment pump characteristic map”
7. Select ”Test plan”
8. Select "Perform adjustment". This sets the adjustment values to
zero.
Note:
Electronics).
Check the stored fault messages.
Rectify the fault.
13 51 005 Statically adjusting injection pump (M47)
Check injection pump measured value,

refer to 13 51 040.
Special tools 13 5 200 and 00 2 510 (dial gauge) remain fitted.
Release plug on injection pump shaft.
Release central nut on injection pump shaft.

In doing so, grip crankshaft at front central bolt.
Screw in and secure special tool 13 5 190 without forcing screw.

Insert jack screw (1) in special tool 13 5 190 and detach sprocket wheel
Remove special tool 13 5 190 together with forcing screw.
Retighten central nut on injection pump to preliminary torque.

Tightening Torque, approx. 30 Nm.

Crank engine in direction of rotation until cast lug (1) on inlet camshaft
points upwards.
Note:
1.
Rotate crankshaft 90° against direction of engine rotation.

Set dial of special tool 00 2 510 (dial gauge) to zero.
(dial gauge) indicates value specified on injection pump exactly.
Release locking screw (1) on injection pump.

Remove spacer plate (2) and tighten down locking screw. The pump
shaft is thus blocked.
Tightening Torque,
Release central nut on injection pump shaft.
Screw in and secure special tool 13 5 190 without forcing screw.

Insert jack screw (1) in special tool 13 5 190 and detach sprocket wheel
Drive and pump are thus separated.
Remove special tool 13 5 190 together with forcing screw.
Lay special tool 11 2 300 (plug mandrel) parallel to speed sensor (1) on
reinforcing rib of engine.
(plug mandrel) audibly snaps into place.
Note:
1.
Tighten central nut on injection pump shaft to preliminary torque.

Tightening Torque,
Release locking screw (1) on injection pump.
Insert spacer plate and tighten down screw.
Tightening Torque,

Tighten down central nut on injection pump shaft.
In doing so, grip crankshaft at front central bolt.
Tightening Torque,
Check O-ring on plug of injection pump shaft, replace if necessary.

Tighten plug.
Tightening Torque,
Check injection pump measured value,
refer to 13 51 040.
Assemble engine.
13 53 588 Checking injectors (without piezo-technology) with return flow
quantity meter

13 0 200
Important!
Return flow quantity measurement is possible with tool 13 0 200
only on injectors without piezo-technology.

Position special tool 13 0 200 securely in engine compartment (secure

against falling off/down).
1. Connections of BMW diagnosis system MFK2+ and MFK2-.
2. Connection, ground to body.
3. Connection, battery positive.
4. Connection OUT.
5. Connection IN.
6. Connection, return temperature sensor.
7. Connections of BMW diagnosis system MFK1+ and MFK1-.
Connect grounding cable (1) of special tool 13 0 200 to body connection

point (2).
Connect positive lead (4) of special tool 13 0 200 to jump start
connection point (3).
Release retaining ring (1) on injector.
Detach leakage oil line (2) in direction of arrow.
Connect OUT line of special tool 13 0 200 to leakage oil line (1).
Connect IN line to injector and secure against falling out with retaining
ring.
Installation:
Check O-ring for damage, replace if necessary.
Follow diagnosis instruction.

13 53 ... Cleaning injector sockets (M67/M57/M57TU/M57T2/M47TU/M47T2)

13 5 210
13 5 214
13 5 215
Remove injectors.Note:
Illustration shows M67 engine.
Seal off hole in injector socket using special tool 13 5 215 in combination
with special tool 13 5 214 .Important!
Injector sealing ring must not remain in injector socket.
Detach special tool 13 5 214 from special tool 13 5 215 .

Remove fitting rod from injector socket.
Insert brush holder and brush head of special tool 13 5 210 in the guide
sleeve.
Insert special tool 13 5 210 in the injector socket and push fully home.
Fit socket on special tool 13 5 210 and turn with a slight amount of
pressure.
Clean sides of injector socket by pushing special tool 13 5 210 in and

out.
Warning!
Always wear safety goggles as there is an risk of eye injury.
Blow out injector socket with compressed air while covering the hole with
a cloth to catch dirt particles.
Check whether the sealing face is clean.
If necessary, repeat cleaning procedure.
After cleaning, remove special tool 13 5 215 and special tool 13 5 214
from the injector socket.
13 53 ... Layout of common rail system (M47TU / M47TU2)
1 Pressure line, cylinders 1 and 3 5 Pressure sensor

2 Pressure line, cylinders 2 and 4 6 Pump line
3 Injectors 7 Rubber mount
4 High-pressure accumulator 8 H.P. pump
9 Pressure regulator
13 53 320 Removing and installing/replacing all injector nozzles (M47)
Caution!

malfunction.
Disconnect all injection lines.
Pull off leak oil hoses using pliers.Installation:

Replace leakage oil hoses.
Release nuts on injector nozzle assemblies.
Screw special tool 13 5 250 onto injector nozzle assemblies and

remove.Installation:
Before installing injectors, clean injector shafts.
Installation:
Injector nozzle assemblies with needle motion sensors (cable
outlet with plug) must always be fitted at cylinder 4.
Replace sealing ring on injector nozzle.
Note:
If more than 2 injector nozzles have been replaced, ”Pump map
adjustment” must be carried out:
1. Connect DIS Tester

2. Identify car
3. Select ”Function selection”
4. Select ”Service functions”
5. Select ”Digital Diesel Electronics (DDE)”
6. Select ”Pump map adjustment”
7. Select ”Test schedule”
8. Select ”Carry out adjustment”. The adjustment values are thus set
to zero.
Note:
Electronics).
Rectify faults.
13 53 315 Removing and installing/replacing all injectors in fuel injection
system (M47TU, M47T2)

13 5 020
13 6 100
Important!
malfunction.
Important!
It is essential to adhere to conditions of absolute cleanliness when
carrying out repair work on the fuel system.
Do not allow any dirt particles or foreign bodies to get into the
system
Use only fluff-free cloths
Remove all traces of dirt contamination before dismantling lines or
separate components
Seal all fuel system openings with protective caps.
Recycling:

Read out the fault memory of the DDE control unit
Switch off ignition
Disconnect all leakage oil lines
Use special tool 13 5 020 to release union nuts (1) of pressure lines (2)
on injector (4) and slacken pressure accumulator.Note:
Reset special tool in good time to prevent bending of pressure lines.
Unscrew nut (3).
Remove injectors (4).
Important!
Risk of injector breakage! Observe tightening torques of union nuts
without fail.
1. Hand-tighten all union nuts on pressure lines.

2. Tighten union nuts on injectors to specified torque.
3. Tighten union nuts on pressure accumulator and high pressure
pump.
4. Perform visual inspection for tightness of all common rail system
components.
If injectors are stuck, fit special tool 13 6 100 to injector connection.

Pull out injector by means of short back and forth movements.
Important!
The freedom of movement of the removal rod is restricted to a few
degrees by the flank clearance of the flange.
Note:
Check whether sealing ring (1) has remained on removed injector.
If this is not the case, sealing ring (1) must be removed from cylinder
head.
Installation note:
Renew sealing ring (1) on injector (2).
Renew sealing ring on slot.
Observe installation position of flange (3).
Lightly lubricate injector slot with highly heat-resistant grease (refer to

Consumables 4.5).
Prior to installation of injector, clean injector slots.
If one or more injectors have been replaced, "injector quantity

compensation" must be performed:
Identify vehicle
Select "Function selection"
Select "Service functions"
The IMA codes must be read off in each case when new injectors are
installed.
EU3 : The adjustment value (6-position letter/number code) is engraved
on each injector.
EU4 : The adjustment value (7-position letter/number code) is engraved
on each injector.
The digits / letters correspond to the installation location (cylinder) of the
new injectors.
Select ”Digital Diesel Electronics”
Select ”Adjustment, injection quantity compensation”
Select "Test schedule"
The adjustment must be entered for each cylinder on which an
injector has been replaced.
It is necessary to adjust the new injectors to ensure their full operability.
Note:
Delete fault memory
13 53 155 Removing and installing/replacing pressure accumulator of
injection system (M47TU)
Remove all pressure lines.
Caution!
malfunction.
Recycling:
Detach plug (1) from pressure sensor (2).

Detach plug (7) from pressure regulator (8).
Release clamp (4).
Detach hose.
Release banjo bolt when replacing pressure accumulator.
Installation:
Replace gaskets.
Tightening torque of banjo bolt, 13 53 14AZ.
Slacken injector-side union nuts on H.P. lines.

Release all union nuts on pressure accumulator.
Tightening torque of all union nuts, 13 53 8AZ.
Release screws.
Remove pressure accumulator.
13 53 560 Removing and installing/replacing pressure sensor on pressure
accumulator of injection system (M47TU)
Read out fault memory of DDE control unit. Turn off ignition.
Disconnect and connect intake air manifold.
Cover intake ducts.
Caution!
malfunction.
Recycling:
Disconnect plug (1).

Release clamp (4).
Detach return hose.
Remove pressure lines (5).
Release union nut (6).
Tightening torque of all union nuts.
Note:
Grip at hexagon head (2) when removing pressure sensor.
Release hexagon screw connection (3) on pressure accumulator.
Installation:
Secure position of pressure sensor and grip at hexagon head (2).
Tighten down hexagon screw connection (3).
Tightening torque of pressure sensor.
13 53 200 Replacing all injection lines (M47)
Caution!

malfunction.
Removing intake air manifold:

Refer to 11 61 050.
Cover intake ducts.
Release union nuts on all injector nozzles with special

tool 13 5 020.Note:
Adjust position of special tool at early stage to prevent any bending
of injection lines.
Plug openings with caps.
Installation:
Tightening torque:
Refer to Technical Data 13 53 7AZ.

Release screws (1) and (2) on connecting bridge.
1. Release union nuts on injection lines of cylinders 3 and 4.

Disconnect rear injection lines.
2. Release union nuts on injection lines of cylinders 1 and 2.
Disconnect front injection lines.
Note:
Installation:
Tightening torque:
Refer to Technical Data 13 53 6AZ.
13 53 330 Replacing all leakage oil lines (M47TU, M47T2)

Read out the fault memory of the DDE control unit
Switch off ignition
Important!
malfunction.
Loosen screws.
Unlock and pull off connector from injectors.
Note:
This procedure is applicable to all injectors.
Press in clamp (1).

Detach connection of leakage oil line (2) upwards.
Important!
Coat sealing ring (1) with lubricant before connecting leakage oil line
(2) to injector.
Check sealing ring for damage; damaged sealing rings can cause
malfunctions when fuel pressure is built up.
If sealing ring (1) is damaged, entire leakage oil line (2) of a cylinder
group must be replaced.
Pull off leakage oil line from T-piece of return line.

13 53 170 Replacing all pressure lines (M57 / M57TU)

13 5 020
The work steps are shown on the M57.
Read out fault memory of DDE control unit. Turn off ignition.
Layout of common rail system (M57 / M47TU / M57TU).
Remove and install intake air manifold.
Cover intake ducts.
Important!
malfunction.
Important!
After disconnecting the pressure lines, it is absolutely essential to
seal the injectors and the high-pressure accumulator with protective
caps.
Do not mix up new pressure lines.
- Even final digit of Part No. = cylinder 2, 4, (6)

- Odd final digit of Part No. = cylinder 1, 3, (5)
Recycling:
Release all union nuts on pressure lines with special tool 13 5 020 .Note:
Reset special tool in good time to prevent bending of pressure
lines.
Important!
Risk of injector breakage! Observe tightening torque 13 53 8AZ
without fail.
1. Replace pressure lines.

2. Hand-tighten all union nuts on pressure lines.
3. Tighten down union nuts on injectors to specified torque.
4. Tighten down union nuts on pressure accumulator and on H.P.
pump.
5. Check all components of common rail system for leaks.
13 53 180 Replacing pressure line (between high-pressure pump and
pressure accumulator) (M57 / M47TU / M57TU / M47T2)

13 5 020
Layout of common rail system.

Cover intake ducts.
Disconnect and connect intake air manifold.
Important!
malfunction.
Important!
After disconnecting the pressure line, it is absolutely essential to
seal the openings in the high-pressure pump and the high-pressure
accumulator with protective caps.
Recycling:
Release union nuts (1) on pressure line with special tool 13 5 020 .
Pull off plug (2).
Remove rubber mount (3).
Installation:
Observe installation position of rubber mount (3).
13 61 501 Replacing control unit (DDE) for M47 and M57
Follow instructions for removing and installing electronic control units,


Installation location of control unit:

Release screws (1) and remove cover.
Tightening torque,

Unlock glow plug relay (2) with a screwdriver (3) and remove towards top.
Disconnect plug connections from control unit (1).

Place glow plug relay (2) together with positive lead to one side.
Unlock retaining clips (3) and take out control unit towards top.
Installation:
Program DDE control unit,
refer to 12 14 705.
13 61 501 Replacing control unit (DDE) for M47TU
Follow instructions for removing and installing electronic control units.


Installation location of control unit:

Release screws (1) and remove cover.
Disconnect plug connections (1) from DDE control unit.

Withdraw control unit from electronics box.
Installation:
Program DDE control unit.
13 62 520 Removing and installing / replacing pedal travel sensor (M47 /
M57)
Turn off ignition.
Remove trim panel for pedal assembly,

refer to 51 45 185.
Location:
Pedal travel sensor (1) is attached to pedal assembly near steering
column (2).
Press accelerator pedal down to full-throttle stop.

Unhook cable of pedal travel sensor (1) from accelerator pedal (2).
Release screws (1).Installation:
Nut of upper screw is accessible through opening in bracket for
steering column.
Place nut of upper screw in an offset ring wrench and secure nut
against dropping out. Join nut with box wrench to securing eye and
grip firmly. The upper screw can then be tightened.
Turn pedal travel sensor (1) and feed past securing eyes of pedal block.
Feed out travel value sensor between steering column and brake pedal.
Layout of pedal travel sensor:

1. Cable pulley
2. Securing nut
3. Cable to accelerator pedal
Installation:
Feed in pedal travel sensor with cable (1) and pulley (2) and wiring
outlet towards top.
Installation:
Feed in pedal travel sensor (1) at an angle from below with securing
eye (2) past steering column and crash disk (3).
Ensure that crash disk (3) is correctly seated on crash sleeve.
Installation:
Turn securing eyes of pedal travel sensor (2) behind retaining lugs
(1) of pedal block.
Adjustment dimension, LHD vehicle:

Observe installation dimension A of cable pulley (1) on pedal travel
sensor (2):
1. Cable pulley
2. Pedal travel sensor
3. Wiring outlet
Caution!
Observe position of wiring outlet (3) when adjusting.
Measurement A: 58°
Install nut, grip cable pulley and tighten nut to specified torque.
Tightening torque,
Adjustment dimension, RHD vehicle:

Observe installation dimension A of cable pulley (1) on pedal travel
sensor (2):
1. Cable pulley
2. Pedal travel sensor
3. Wiring outlet
Caution!
Observe position of wiring outlet (3) when adjusting.
Measurement A: 75°
Install nut, grip cable pulley and tighten nut to specified torque.
Tightening torque,
Perform function check:

Check idling and full-throttle positions with DIS Tester or MoDiC.
If the idle speed value is not achieved, the cable pulley of the pedal
travel must be readjusted.
If the idle speed value is reached but not the full load value, the
mechanical full load stop on the accelerator pedal must be corrected.
Note:
Electronics).
Rectify faults.
13 62 560 Removing and installing/replacing air-mass flow sensor (M47)
Turn off ignition.
Release expansion rivets (1). Push cover approx. 2 cm towards rear and
lift out towards top.
Note:
Release screws (1 and 2) and remove front acoustic cover.
Release screws (1) and detach intake neck.

Tightening Torque,
Disconnect plug connection from air-mass flow sensor.

Release screws (1) and remove air-mass flow sensor.
Tightening Torque,
Read out fault memory of DDE control module, check stored error
messages, rectify faults, clear fault memory.
13 62 560 Removing and installing/replacing air-mass flow sensor (M47TU)
Turn off ignition.
Remove fan cowl.
Release screws.
Release screws (1).

Detach intake pipe a little in direction of arrow.
Raise intake pipe (1) a little.

Unclip lines (2) from upper bracket.
Detach hose (3) on air cleaner housing.
Unclip lines (1) from lower bracket.
Detach hose (2).
Remove intake pipe (3).
Installation:
rings (1).
Disconnect plug connection (2) on air-mass flow sensor.

Release screws (1).
Remove air-mass flow sensor.
Rectify fault and clear fault memory.
13 62 650 Replacing camshaft pulse generator (M47TU / M57TU / M47T2)

Read fault memory of DDE control unit
Switch off ignition
Remove acoustic cover at front
Remove sealing cap (1).

If necessary, remove rubber sleeve (2).
Unlock plug (3) from pulse generator and detach.
Release screw (4).
Remove pulse generator (5).
Installation:
Apply a thin coat of anti-friction agent to sealing ring (1) for installation.
Installation:
13 62 535 Replacing charge-air pressure sensor (M47)
Turn off ignition.

Remove heater bulkhead, refer to removal of cowl panel cover,
refer to 51 13 115.
Installation location of temperature sensor:

Rear of intake air manifold (2).
Release screw (1). Remove charge-air pressure sensor (2).

Tightening Torque,
Installation:
Check seal of charge-air pressure sensor for damage, replace seal
if damaged.
Read out fault memory of DDE control module, check stored error
messages, rectify faults, clear fault memory.
13 62 535 Replacing charge-air pressure sensor (M57 / M47TU)
Turn off ignition.
E46/E53 only:
Installation location of charge-air pressure sensor:

On intake air manifold, rear
(Fig. E39).
Disconnect plug (1).

Release screw (2).
Remove charge-air pressure sensor (3).
Installation:
Check sealing ring (1) of charge-air pressure sensor and replace if
damaged.
For assembly, apply a thin coat of petroleum jelly to sealing ring (1)
of charge-air pressure sensor.
Rectify fault and clear fault memory.
13 62 531 Replacing coolant temperature sensor (M47)
Caution!

malfunction.
Note:
refer to 11 61 050.
Disconnect plug connection for needle motion sensor (1) at cable duct.
If necessary, pull plug from glow plug, cylinder 4.
Release union nuts on injector nozzles, cylinders 3 and 4, with special

tool 13 5 020.Note:
Adjust position of special tool at early stage to prevent any bending
of injection lines.
Installation:
Tightening torque,
Release screw (1) on connecting bridge.
Release union nuts (1) on injection lines of cylinders 3 and 4.

Disconnect rear injection lines.
Note:
Installation:
Tightening torque,

Remove temperature sensor (2).
Tightening torque,
Note:
Electronics).
Rectify faults.
13 62 610 Replacing crankshaft pulse generator (M47TU / M57TU / M47T2 /
M57T2)

Read fault memory of DDE control unit
Remove starter motor
Pull plug (1) off pulse generator.

Detach mating connectorÂ (2) from holder.
Unscrew bolt (3).
Remove pulse generator.
Clear DDE fault memory.

13 62 600 Replacing speed sensor (pulse generator) (M47)

Remove and install starter motor,
refer to 12 41 020.
Lever out expansion rivets and lift off intake hood (1).
Push radiator hose (1) to one side and look past deflection pulley (2) at
vibration damper.
Rotate crankshaft in direction of engine rotation until notch in vibration

damper (1) is flush with cast lug on timing case cover (2).
Disconnect plug connection (1) at speed sensor.
Release screw (2) and remove speed sensor together with retainer.
Release screw and detach speed sensor from retainer.
Mount special tool 13 6 040 on holder.

Mount holder on engine block and push forward as far as stop.
Tighten holder.
Caution!
Retainer may no longer be detached from engine block.
Note:
Special tool 13 6 040 must rest against sensor pin (1) of flywheel.
The required clearance between the sensor pin on the flywheel and
the speed sensor is thus adjusted.
Release special tool 13 6 040 from retainer and remove.
Mount speed sensor and tighten down.

Add final details to vehicle.
Switch on ignition. Check function.
Read error memory on DDE control unit, check faults in memory, rectify
faults then clear the error memory.
13 72 001 Replacing air cleaner element (M47TU)
Remove microfilter.
cable(s).

Unfasten screws.
Unfasten screws.
Release air funnel in direction of arrow and remove.
Unfasten screws.
Lift off air cleaner housing.
Note:
Fig. M47.
Installation:
13 72 001 Replacing air cleaner insert (M47)
Remove microfilter.
cable(s).
Note:
Release screws, lift off front acoustic cover.
Remove intake neck.
Note:

Installation:
Install cleaner insert with support (1) towards bottom.
16 11 130 Checking filler cap pressure relief valve

13 3 010
16 1 171
16 1 172
16 1 173
Set pressure regulator on special tool 16 1 171 fully in ”-” direction.

Connect special tool 16 1 171 via compressed air line (1) to garage
compressed air system (8...10 bar).
Connect pressure sensor (2) of Diagnosis and Information System with a
measuring range of 0...3.5 bar.
Select special tool 16 1 172 or 16 1 173 matching vehicle's filler cap and
attach to quick release coupling of special tool 16 1 171 .
Install filler cap on selected special tool (3).
Note:
Only the absolute pressure is indicated in the display of the
Diagnosis and Information System (DIS). The current ambient air
pressure is already displayed without additional pressurization.
Check testing equipment for leaks!
Select ”Measurement” function on Diagnosis and Information System
(DIS).
Set measuring range according to pressure sensor to 0-3.5 bar.
Increase pressure by 0.2 bar with pressure regulator on special tool
16 1 171 .
Using special tool 13 3 010 , disconnect delivery line from special tool
16 1 171 to tank filler neck.
Wait 60 secs.
Read off final pressure value and compare with starting pressure value.
Measurement evaluation:
Pressure drop > 0.012 bar Testing equipment leaking.

Check connection points for leaks.
Check filler cap pressure relief!

Follow same test procedure as for ”Checking testing equipment for
leaks”.
16 1 171 .
Pressure drop > 0.012 bar Filler cap pressure relief valve faulty.
Replace filler cap.
16 00 100 Checking fuel tank and tank ventilation system for leaks

13 3 010
16 1 157
16 1 171
16 1 174
Note:
The following procedure is only applicable to vehicles without the
tank leak diagnosis module (DM-TL).
Vehicles with carbon canister only

A leak test must be carried out if a leak is suspected in the tank
ventilation system.
Vehicles with leak diagnosis pumps (LDP)

If a leak in the tank ventilation system is indicated by the ”Check
engine” indicator lamp in the instrument cluster lighting up, a leak
test must be carried out.
Read out the fault memory of the DME control unit and carry out a
diagnosis. If the sensors are OK, then begin the leak test.
The following conditions must be observed to obtain plausible measuring

results:
Contents of fuel tank 50 % ± 25 %
Park the car in the workshop at least 2 hours before the test so that
the fuel temperature is approximately that of the workshop
temperature
(ideal fuel temperature approx. 10...20°C).
Never refuel the vehicle directly prior to the leak test
due to the strong emission of gas by the fresh fuel.
Release screws (1/3), remove panel (2).

Remove expansion rivet (4), remove panel (5).
Applicable to vehicles with leak diagnosis pumps (LDP) only.
Unlock line (3) and detach from dust filter.
Seal dust filter with special tool 16 1 157 .
Applicable to vehicles only equipped with a carbon canister only.

Release lock of line (1), detach line from carbon canister (5).
Seal opening on carbon canister with special tool 16 1 157 .
Remove tank cap and connect special tool 16 1 174 to tank filler neck.
Using adjusting wheel (1), clamp special tool 16 1 174 firmly to tank filler
neck.
Caution!
Connect special tool 16 1 171 using compressed air line (1) to garage
Connect pressure sensor (2) of Diagnosis and Information System with
Caution!
Do not connect fast-release coupling (3) of special tool 16 1 171
yet.
(DIS).
Set measuring range in accordance with pressure sensor to 0-3.5 bar.
Using pressure regulator on special tool 16 1 171 , increase pressure by
0.050 bar.
Connect special tool 16 1 174 to fast-release coupling of special tool
16 1 171 .
Using pressure regulator on special tool 16 1 171 , reset gauge pressure
in fuel tank to 0.050 bar.
Caution!
Do not under any circumstances increase pressure by more than
0.100 bar as this would result in damage to the fuel tank and venting
system.
Using special tool 13 3 010 , disconnect supply line from special tool
Allow a rest period of approx. 20 secs.
Read off and note down starting pressure value, then wait 60 secs.
Pressure drop between 0.008 and Measure again.

0.010 bar.
Pressure drop in 60 secs. greater System leaking beyond
than 0.010 bar. permitted levels.
Carry out leak test.
16 00 009 Cleaning complete fuel system (in event of incorrect filling of
diesel cars with petrol/gasoline)
Important!
Do not start engine!
Please refer to the current Service Information bulletins and

PuMA measures for the exact procedure in the event of diesel
vehicles being incorrectly filled with petrol/gasoline.
16 00 005 Draining and filling fuel tank
Caution!
Observe according country safety legislation and regulations!
Ensure adequate ventilation in the place of work!
Connect exhaust extraction unit to exhaust tailpipe.
The electric fuel pump must not operate without fuel! After
completing repairs and before starting engine for first time, fill fuel
tank through fuel filler pipe with min. 5 ltr. fuel.
Carefully withdraw extraction hose so as not to damage non-return
flap.
After completing repairs and before starting engine for first time, fill fuel
tank through fuel filler pipe with min. 5 ltr. fuel.
M47, M57
Before starting the engine for the first time, if the tank has been run
empty or drawn off, pour in diesel fuel and turn on ignition for approx. 1
minute. The fuel circuit is thus filled and vented, which results in the
engine firing more quickly.
Drawing off fuel:

Start engine and allow to run. Electric fuel delivery pump runs.
This pumps the fuel through the suction jet pump and the tank expansion
line from the left to the right side of the fuel tank.
Note:
Fuel can be drawn off from the left and right tank halves through the fuel
filler pipe down to a small residual amount. This residual amount is drawn
off after removal of the sensors for the fuel gauge (right/left).
Slide extraction hose of extractor unit,

refer to BMW Service Workshop Equipment & Planning documentation,
into filler pipe, turning hose slightly if necessary.
Insertion length:
130 cm
Draw off fuel with extractor unit,
as far as possible.
Follow the fuel drawing-off procedure at the fuel gauge in the instrument
cluster.
Drawing off residual fuel quantity:
Caution!
Ensure the vehicle interior is adequately ventilated.
Catch dripping fuel in a suitable container.
Remove sensor for fuel gauge (right).
Remove sensor for fuel gauge (left).

Draw off residual fuel quantity through installation openings.
Fuel filling:
Slide extraction hose of extractor unit,
approx. 40 cm into filler pipe.
Fill fuel from extractor unit.
Drawing off after fault in suction jet pump:

Draw off right half of tank completely through filler pipe.
Remove sensor for fuel gauge (left).
Insert extraction hose through sensor opening in tank, fuel (also residual
quantity) can be drawn off.
16 00 Fuel supply system E46 (diesel engines)
1. General
General function description for fuel systems.
2. Parts designation
1. Fuel tank 14. Service vent line

2. Electric fuel supply pump 15. Expansion tank
3. Surge chamber 16. Roll-over valve
4. Suction jet pump 17. Distributor injection pump (M47)
5. Tank expansion line 17. High-pressure pump (M57)
6. Outlet protection valve 18. Inline pump (M57)
7. Filler pipe 19. Fuel filter
8. Tank cap 20. Fuel rail (M57)
9. Refueling vent line 21. Injection nozzle
10. Fuel return line 22. Bimetallic valve
11. Fuel feed line 23. Fuel cooler
12. H-piece 24. Pressure limiting valve (M57)
13. Service vent line
3. Function description (see also drawing 5.1 / 5.2)

Fuel system (see drawing 5.1 / 5.2)
The saddle-shaped fuel tank contains the surge chamber with the electric fuel feed supply pump on its right
side.
The surge chamber ensures that the fuel supply pump is properly supplied in all vehicle operating states.
The fuel is repumped from the right side of the fuel tank into the surge chamber via the suction jet pump
integrated in the tank expansion line. The suction jet pump is operated via the fuel feed line.
The outlet protection valve protects the fuel return line. The valve closes in the event of a pressure drop when
the fuel return line is damaged or disconnected.
This prevents fuel from escaping from the fuel tank in extreme vehicle positions (overturning, inclined position).
Fuel supply to engine:
M47 (see drawing 5.1)
The fuel is routed from the electric fuel supply pump via the fuel feed line and the fuel filter to the distributor
injection pump.
The distributor injection pump supplies the relevant injection nozzle.
The return fuel from the fuel injectors and the distributor injection pump is directed to the bimetallic valve, which
divides the amount of return fuel as a function of the fuel temperature.
At low fuel temperatures, the greater part of the fuel flows back into the fuel feed line ahead of the fuel filter. In
this way, the fuel is heated up faster at low outside temperatures.
At high fuel temperatures, the greater part of the fuel flows back into the fuel tank via the fuel cooler and the
fuel return line. This prevents the fuel from being excessively heated at high outside temperatures.
Large and heated amounts of return fuel occur under extreme operating conditions such as e.g. uphill driving or
trailer towing. For this reason, part of the fuel is routed directly into the fuel feed line by the flow restrictor in the
H-piece. This measure also counteracts any excessive heating of fuel in the fuel tank.
M57 (see drawing 5.2)
The fuel is routed from the electric fuel supply pump via the fuel feed line, the inline pump and the fuel filter to
the high-pressure pump.
The high-pressure pump supplies the injection nozzles with fuel via the fuel rail.
The inline pump generates the necessary preliminary fuel pressure for the high-pressure pump. This
preliminary pressure is maintained at a constant level by the pressure limiting valve in the engine circuit.
The return fuel from the fuel injectors and the high-pressure pump is directed to the bimetallic valve, which
divides the amount of return fuel as a function of the fuel temperature.
At low fuel temperatures, the greater part of the fuel flows directly into the fuel feed ahead of the inline pump. In
this way, the fuel is heated up faster at low outside temperatures.
At high fuel temperatures, the greater part of the fuel flows back into the fuel tank via the fuel cooler and the
fuel return line. This prevents the fuel from being excessively heated at high outside temperatures.
Large and heated amounts of return fuel occur under extreme operating conditions such as e.g. uphill driving or
trailer towing. For this reason, part of the fuel is routed directly into the fuel feed line by the flow restrictor in the
H-piece. This measure also counteracts any excessive heating of fuel in the fuel tank.
Venting system (see drawing 5.1 / 5.2)
The fuel tank is vented during refueling via the refueling vent line in the filler necks.
During driving, the fuel tank is vented via the service vent lines and the expansion tank.
The condensed constituents of the fuel vapors pass from the expansion tank via the left service vent line
back into the fuel tank.
Determining fill level in fuel tank
The fuel level is measured by means of lever-type sensors on both sides of the fuel tank. The right lever-type
sensor is integrated in the fuel supply unit. The left lever-type sensor is located in the left sensor unit. The
combination of the determined ohm values from the right and left lever-type sensors produces the actual level
in the fuel tank.
4. Service data, fuel system
Working pressure of fuel supply pump: 0.4 bar
Working pressure of suction jet pump: 1 - 1.3 bar
5. Schematic drawings of fuel supply systems
5.1 Fuel supply system E46 M47
5.2 Fuel supply system E46 M57
16 00 Fuel supply system E46 (spark ignition engines)
1. General
General function description for fuel systems.
2. Parts designation
1. Fuel tank (plastic) 18. Roll-over valve

2. Electric fuel supply pump 19. Float valve (USA only)
3. Surge chamber 20. Fuel filter
4. Pressure limiting valve 21. Pressure regulator
5. Outlet protection valve 22. 3/2-way valve (M52 USA, M73 only)
6. Suction jet pump 23. Fuel rail
7. Tank expansion line 24. Engine control unit
8. Non-return flap 25. Intake manifold
9. Filler pipe 26. Tank vent valve
10. Tank cap 27. Purge line
11. Pressure test line (USA only) 28. Vent line
11. Refueling vent line (worldwide) 29. Vacuum line (LDP USA only)
12. Fuel feed line 30. Evaporation line
13. Fuel return line 31. Carbon canister
14. Service vent line 32. Carbon canister (USA only)
15. Refueling vent line (USA only) 33. Leakage diagnosis pump (USA only)
15. Additional vent line (Japan) 34. Dust filter (USA only)
16. Service vent line 35. Tank leakage diagnostic module (USA only)
17. Expansion tank
3. Function description (see also drawing 5.1 / 5.2 / 5.3 / 5.4)

Fuel system
The saddle-shaped fuel tank contains the surge chamber with the electric fuel feed supply pump on its right
side.
The surge chamber ensures that the fuel supply pump is properly supplied in all vehicle operating states.
The fuel is repumped from the right side of the fuel tank into the surge chamber via the suction jet pump
integrated in the tank expansion line. The suction jet pump is operated via the fuel feed line.
The pressure limiting valve controls the pressure required to operate the suction jet pump. The outlet
protection valve protects the fuel return line. The valve closes in the event of a pressure drop when the fuel
return line is damaged or disconnected.
This prevents fuel from escaping from the fuel tank in extreme vehicle positions (overturning, inclined position).
The non-return flap prevents fuel from splashing back in the filler pipe after shutdown of the petrol/gas pump
nozzle.
Fuel supply to engine:
M43TU / M52TU (see drawing 5.1, view A):
The fuel is routed from the electric fuel supply pump via the fuel feed line and the fuel filter to the fuel rail. The
fuel returns to the fuel tank via the pressure regulator secured to the fuel rail and the fuel return line.
M52 USA (see drawing 5.3):
The fuel is routed from the electric fuel supply pump via the fuel feed line and the fuel filter to the fuel rail.
The fuel returns to the fuel tank via the 3/2-way valve (see view A), the pressure regulator and the fuel return
line.
This engine fuel circuit with return from the fuel rail is then switched for engine starting and a defined time < 1
minute.
After this phase, the 3/2-way valve switches and interrupts the fuel return from the fuel rail. At the same time,
the line branch directly at the fuel filter is activated by the 3/2-way valve to the pressure regulator (see view B).
The fuel rail is now return-free.
M54 / M54 USA (see drawing 5.1, view and drawing 5.4):
Pressure regulator and fuel filter are incorporated in a single unit.
The fuel is routed from the electric fuel supply pump via the fuel feed line and the fuel filter/pressure regulator
unit to the fuel rail.
The fuel rail is return-free. The fuel flows directly from the fuel filter/pressure regulator unit back into the fuel
tank.
Venting system USA (see drawing 5.3 / 5.4)
The fuel tank is vented during refueling via the refueling vent line.
Because of its large cross-section, the refueling vent line directs the displaced volume (fuel vapors) at high
speed through the expansion tank to the carbon canister.
The activated carbon retains the fuel contained in the fuel vapors. The cleaned air is discharged to
atmosphere via the evaporation line, the leakage diagnosis pump or the tank leakage diagnostic module and
the dust filter.
During driving, the system tank is vented in the same way via the refueling vent line and service vent lines.
The condensed constituents of the fuel vapors pass from the expansion tank via the left service vent line
The float valve in the expansion tank is closed by the rising fuel if the tank is overfilled. This prevents
overflowing of the expansion tank.
The roll-over valve on the upper side of the expansion tank closes in the event of the vehicle overturning. This
prevents the fuel from escaping into the carbon canister. The carbon canister is regenerated by purging with
fresh air.
The engine control unit opens the tank vent valve. Thus the vacuum pressure of the engine intake manifold is
applied at the purge line.
The carbon canister is purged in this way. The fresh air needed for this purpose is supplied via the leakage
diagnosis pump or the tank leakage diagnostic module and the dust filter. The fuel constituents bound by the
activated carbon are flushed out by the supplied air and directed via the purge line to the engine for
combustion.
This operation is only possible while the engine is running.
Venting system worldwide (see drawing 5.1)
Refer to Venting system USA with following differences:
1. During refueling, the fuel tank is vented via the refueling vent line, which directs the displaced volume into
the filler neck. There is a second service vent line with a smaller cross-section in place of the refueling
vent line (USA) with large cross-section. There is no float valve.
2. The carbon canister has a smaller capacity.
3. There is no leakage diagnosis pump/tank leakage diagnostic module or dust filter.
4. For Japanese vehicles, the refueling vent line (USA) is replaced by an additional vent line with a float
valve in the expansion tank, which is connected to the refueling vent line (worldwide).
This modification is required on account of the more heavily gas-emitting fuel in Japan (see drawing 5.2).
Leakage detection for tank venting system USA (see drawing 5.3 / 5.4)
The leakage diagnosis pump or tank leakage diagnostic module serves to detect leakages for the tank
venting system within the on-board diagnosis laid down by legislation.
The tank venting system is pressurized and the pressure loss is detected in the event of a leak.
With the leakage diagnosis pump, the pressure loss is measured by way of the repumping time. The pump is
operated with vacuum pressure from the intake manifold via the vacuum line.
The tank leakage diagnostic module detects the pressure loss by way of the power consumption of the
integrated pump. The air required for this purpose is supplied via the dust filter.
Both systems are activated by the engine control unit.
The pressure test line establishes the connection between fuel tank and filler neck. This enables a leak to be
detected in the filler pipe - tank cap area.
Determining fill level in fuel tank
The fuel level is measured by means of lever-type sensors on both sides of the fuel tank. The right lever-type
sensor is integrated in the fuel supply unit. The left lever-type sensor is located in the left sensor unit. The
combination of the determined ohm values from the right and left lever-type sensors produces the actual level
in the fuel tank.
4. Service data, fuel system
Pressure regulator: 3.5 bar.
Working pressure of suction jet pumps: 1 - 1.3 bar
5. Schematic drawings of fuel supply systems
5.1 Fuel supply system E46 with M43TU / M52TU / M54

5.2 Fuel supply system E46 with M43TU / M52/TU M54 Japan
5.3 Fuel supply system E46 with M52 USA
5.4 Fuel supply system E46 with M54 USA
16 00 Functional description for general fuel supply systems
Petrol engine fuel supply systems
Fuel system
The fuel pump in the fuel tank generates pressure in the fuel system, which is set by the electronic
pressure control valve to a certain level.
Tank-venting system
The tank safety valve is a closed system that is bled via a carbon canister. The carbon in the canister is
stored as granules. The large surface of the granules traps the fuel vapour, that occurs in the fuel tank. The
carbon canister needs to be refreshed regularly in order to be able to continue to store fuel vapour. This is
done by flushing it with fresh air from the intake pipe. This process is controlled by the engine control unit.
Diesel engine fuel supply system
Fuel system
The fuel pump in the fuel tank supplies the engine with fuel. Two types of high pressure pump are used for
direct injection.
1. The distributor-type injection pump. This supplies each cylinder directly with fuel via individual injector
nozzles.
2. The high pressure pump for the common rail systems. This generates the required pressure in the
injector pipe for all injector nozzles.
With common rail systems another pump (inline pump, M57/geared pump, M67) is connected between the
high pressure pump and the fuel pump. This pump aids the fuel pump in the fuel tank during times of high fuel
requirement.
Tank-venting system
Diesel fuel is slow-evaporating, therefore no carbon canister is required. The fuel tank is bled directly into
the atmosphere.
16 00 ... Layout of fuel supply system (KVA)
Layout / function description of fuel supply system (KVA)
1 Filler pipe with unleaded flap and non-return 9 Vent line, right, for service venting
flap
10 Vent line from expansion tank to activated carbon
2 Fuel tank canister
3 Fill level sensor, left 11 Scavenging air line to engine
4 Fill level sensor, right, with electric fuel pump 12 Evaporation line to atmosphere
(EKP)
13 Fuel feed line to fuel filter
5 Expansion tank
14 Return line from engine
6 Carbon canister
7 Vent line for refuelling
8 Vent line, left, for service venting
Functional description of fuel supply system

Refuelling: During refuelling, the fuel is poured through the filler pipe into the right half of the tank. When the
right half of the tank is full, further fuel pours into the left half of the tank. The tank is now
completely full.
An unleaded flap is incorporated in the filler pipe at the top to ensure that only pump nozzles for
unleaded fuel can be inserted.
A non-return flap is located at the bottom end of the filler pipe to prevent fuel from sloshing back
and thus make refuelling easier.
Fuel The electric fuel pump (with suction strainer) draws fuel from the surge chamber and delivers it
delivery: to the fuel filter. The fuel flows from the fuel filter to the engine.
The fuel return line runs from the engine to the left fill level sensor. An overflow line is attached
to the left fill level sensor.
The overflow line integrated in the tank returns the fuel to the right tank half into the surge
chamber. This guarantees a safe fuel supply even when the car is in extreme positions. I
The overflow line incorporates a suction jet pump which pumps the fuel from the left to the right
tank half.
Fuel tank During refuelling, the air displaced from the fuel tank is routed through a vent line to the filler pipe.
ventilation:
There are service vent lines mounted to the left and right sides of the tank. The left vent line
leads to the underside of the expansion tank. The right service vent line is connected via a loop
leading to the left side of the tank to the top of the expansion tank. The loop in the right service
vent line prevents the expansion tank from filling up when the car is in extreme positions. Both
service vent lines serve the purpose of dynamic tank venting when the car is moving.
When the engine is at a standstill, the fuel vapours displaced from the fuel tank are routed
through the expansion tank to the activated carbon canister. The activated carbon in this
canister absorbs the hydrocarbons and clean air is discharged to atmosphere.
When the engine is running at normal operating temperature, the tank venting valve in the
engine compartment is opened in certain operating states. As a result, the partial vacuum
prevalent in the intake pipe causes fresh air to be drawn into the activated carbon canister,
thereby enabling the activated carbon to regenerate. The fuel vapours are drawn in and burned
by the engine.
The expansion tank incorporates a rollover valve which, in the event of the car rolling over,
closes the connection between expansion tank and activated carbon canister, thereby
preventing the fuel from spilling out.
16 11 130 Checking filler cap pressure relief valve

13 3 010
16 1 171
16 1 172
16 1 173

Connect special tool 16 1 171 via compressed air line (1) to garage
Connect pressure sensor (2) of Diagnosis and Information System with a
Select special tool 16 1 172 or 16 1 173 matching vehicle's filler cap and
attach to quick release coupling of special tool 16 1 171 .
Install filler cap on selected special tool (3).
Note:
Only the absolute pressure is indicated in the display of the
Diagnosis and Information System (DIS). The current ambient air
pressure is already displayed without additional pressurization.
Check testing equipment for leaks!
(DIS).
Set measuring range according to pressure sensor to 0-3.5 bar.
16 1 171 .
Using special tool 13 3 010 , disconnect delivery line from special tool
Wait 60 secs.
Pressure drop > 0.012 bar Testing equipment leaking.

Check connection points for leaks.
Check filler cap pressure relief!

Follow same test procedure as for ”Checking testing equipment for
leaks”.
16 1 171 .
Pressure drop > 0.012 bar Filler cap pressure relief valve faulty.
Replace filler cap.
16 11 120 Removing and installing / replacing expansion tank for tank
ventilation
Remove rear right wheel,

refer to 36 10 300
Remove rear right wheel arch trim.
Unfasten plastic nut (1).

Unfasten hose clip (2) and remove hose.
Tilt expansion tank (3) forwards at bottom.
Release hose clip (1) and disconnect hose (2).

Release hose clip (3) and disconnect hose (4).
Remove expansion tank (5).
16 11 030 Removing and installing fuel tank
Caution!
After installation of fuel tank / prior to first engine start-up:
Check resistance between metal filler bowl and wheel hub.
Measured value approx. 0.6 â„¦.
Fill fuel tank with at least 5 liters of fuel.
M47, M57
After introducing fuel, turn on ignition and wait approx. 1 minute. The
fuel system is thus vented, making it easier to start the engine.
Draw off fuel from fuel tank.

Detach handbrake cables from handbrake lever.
Remove propeller shaft.
Remove tension strut on left and right (E46 convertible only).
Remove tank trim on left.
Remove lip (2) on left, pay attention to guide (1) during installation.
Remove tank trim on right.
Remove lip (2) on right, pay attention to guide (1) during installation.
Pull handbrake Bowden cables (1) out of guide tubes.
Release hose clips (1) and detach fuel lines.

2) Feed line
3) Return line
Installation:
Replace hose clips.
Release hose clamp (1) and detach fuel filler pipe-fuel tank connecting
hose from fuel tank.Installation:
Replace hose clips.
Support fuel tank over a wide area with a lifter.

Release hexagon nut (1).
Right
Release screw (1), remove tightening strap (2).
Left
Release screw (1), remove tightening strap (2).
Lower fuel tank and disconnect plug connections.
Release hose clamp (1), disconnect vent line.
Remove fuel tank towards bottom.
Note:
M3 only!
Before installing a new fuel tank, it is absolutely essential to fit the swirl
pot attachment on the swirl pot.
16 11 060 Removing and installing/replacing fuel filler pipe
Caution!
After installing fuel filler pipe, check electrical resistance between
metal filler bowl and wheel hub.
Measured value approx. 0.6 Ω.
Draw off fuel down to below level of filler opening in tank.

16 00 005
Remove rear right wheel.
36 10 300
Release hose clip (1), release plastic nut (2).

Withdraw fuel filler pipe from connecting hose.
Release plastic nuts (1/2).

Withdraw fuel filler pipe (3) from rubber sleeve (4).
Installation:
When installing fuel filler pipe, make sure rubber sleeve (4) is
correctly seated.
For model 46/5 only:
Release plastic nuts (1/2).
Withdraw fuel filler pipe (3) from rubber sleeve (4).
Installation:
When installing fuel filler pipe, make sure rubber sleeve (4) is
correctly seated.
16 12 010 Removing and installing / replacing activated-carbon filter
Release screws and expansion rivet (1), remove panel (2).

Release fastener for lines (1 to 3), detach lines.

Release hexagon screw (4), remove carbon canister (5).

16 12 010 Removing and installing/replacing carbon canister with LDP (leak
diagnosis pump)
Release screws (1), lift out expansion rivet (2) and remove cover (3).
Lever out expansion rivets (4) and remove cover (5).
Unfasten lines (1) ... (3) and detach.

1) Line to expansion tank
2) Scavenging air line
3) Intake line for dust filter
Unfasten plug connection (1).

Release screws (2) and remove carbon canister (3) with leakage
diagnosis pump towards bottom.
Installation:
Press rubber-encased lugs (1) on carbon canister (2) into mountings (3).
16 12 435 Removing and installing/replacing diesel pump (supplementary
delivery pump)
Important!
Recycling:
Catch and dispose of escaping fuel. Observe country-specific
waste-disposal regulations.

Unlock plug (1) and remove.

Release hose clamps (2) and detach fuel hoses (3) from fuel pump (4).
Remove fuel pump (4) with damping ring (5)
Installation:
Check and if necessary replace damping ring (5).
Replace hose clamps.
Note:
M57TU AWD
Unfasten plug connection (1) and disconnect.

Installation:
Installation:
the fuel pre-supply pump is activated and the fuel line to the H.P. pump
vented.
16 12 001 Removing and installing/replacing sensor for fuel gauge (left)
(complete unit)
Draw off fuel from fuel tank,

refer to 16 00 005
Remove rear seat bench.
Fold floor trim (1) towards front.

Disconnect insulating mat (2) at perforation and fold back towards rear,
detach rubber grommet when doing this.
Release hexagon nuts (1) and remove lid (2).Installation note:

Check gasket for lid (2), renew if required.
Release hose clamp (1) and detach hose (2).

Release screw cap with special tool 16 1 020.Installation note:
Renew rubber renew, always insert rubber gasket in the fuel tank
when doing this.
Tighten screw cap to specified torque.
Tightening torque, refer to 16 14 2AZ.
Installation note:
When installing fuel level sensor, make sure that lug (1) engages in
recess (2) on fuel tank.
During tightening to specified torque, notch (3) on screw cap can be
clearly heard and felt to engage toothed segment (4) on fuel tank.
Carefully pull out fuel level sensor.
Press lock (1) and pull off fuel tank expansion line.
Installation note:
Make sure that non-return valve (1) is installed in fuel tank
expansion line.
Note:
Should suction jet pump not work properly, delivery unit (right) must
be removed,
refer to 16 12 000
After removal of fuel gauge sensor (left), check whether fuel tank
expansion line (1) is engaged in surge tank (2).
16 12 000 Removing and installing/replacing sensor for fuel gauge (right)
(complete unit)

16 1 020

refer to 16 00 005

Disconnect insulating mat at perforation and fold back towards rear,

Unlock plug connection (1) and disconnect.

Release hose clamp (2) and pull off hose (3).
Release screw cap with special tool 16 1 020 .Installation note:
when doing this.
Installation note:
16 12 010 Removing and installing / replacing activated-carbon filter
Release screws and expansion rivet (1), remove panel (2).



16 12 010 Removing and installing/replacing carbon canister with LDP (leak
diagnosis pump)
Release screws (1), lift out expansion rivet (2) and remove cover (3).
Lever out expansion rivets (4) and remove cover (5).
Unfasten lines (1) ... (3) and detach.

1) Line to expansion tank
2) Scavenging air line
3) Intake line for dust filter

Release screws (2) and remove carbon canister (3) with leakage
diagnosis pump towards bottom.
Installation:
Press rubber-encased lugs (1) on carbon canister (2) into mountings (3).
16 12 435 Removing and installing/replacing diesel pump (supplementary
delivery pump)
Important!
Recycling:
Catch and dispose of escaping fuel. Observe country-specific
waste-disposal regulations.


Installation:
Note:
M57TU AWD

Installation:
Installation:
the fuel pre-supply pump is activated and the fuel line to the H.P. pump
vented.
16 14 010 Removing and installing/replacing fuel pump (complete sensor
unit)
Note:
This operation is identical to "Removing and installing/replacing fuel
level sensor (complete unit)"
refer to 16 12 000
16 12 001 Removing and installing/replacing sensor for fuel gauge (left)
(complete unit)

refer to 16 00 005

Disconnect insulating mat (2) at perforation and fold back towards rear,

Release hose clamp (1) and detach hose (2).

Release screw cap with special tool 16 1 020.Installation note:
when doing this.
Installation note:
Carefully pull out fuel level sensor.
Press lock (1) and pull off fuel tank expansion line.
Installation note:
Make sure that non-return valve (1) is installed in fuel tank
expansion line.
Note:
Should suction jet pump not work properly, delivery unit (right) must
be removed,
refer to 16 12 000
After removal of fuel gauge sensor (left), check whether fuel tank
expansion line (1) is engaged in surge tank (2).
16 12 000 Removing and installing/replacing sensor for fuel gauge (right)
(complete unit)

16 1 020

refer to 16 00 005

Disconnect insulating mat at perforation and fold back towards rear,


Release hose clamp (2) and pull off hose (3).
Release screw cap with special tool 16 1 020 .Installation note:
when doing this.
Installation note:
16 14 530 Replacing sucking jet pump
Suck the fuel out of the fuel tank,

refer to 16 00 005
Remove fuel level sensor (right),
refer to 16 12 000
Remove fuel level sensor (left),
refer to 16 12 001
Left side:
Pull tank expansion line (1) on fuel baffle (2) out of locking fixture.
Installation:
Ensure that tank expansion line is perfectly connected in fuel baffle.
Right side:
Remove tank expansion line from fuel tank.
Installation:
Tank expansion line must not be bent when it is being removed.
Installation:
Ensure that non-return valve (1) is fitted in tank expansion line.
equipment)
Warning!
Important!
direct sunlight.
Important!
Important!
fumes directly.
agent/paint.
cream.
Important!
First Aid:
Recycling:
17 00 009 Checking cooling system for watertightness

17 0 002
17 0 005
17 0 007
17 0 008
Warning!
Risk of scalding!
Checking pressure drop in cooling system:

Remove sealing cap on expansion tank. Fit special tool 17 0 002
/ 17 0 005 .
Build up excess pressure of 1.5 bar, wait approx. 2 minutes.
Cooling system is impervious to leaks if pressure drop is max. 0.1 bar.
Checking pressure relief valve in sealing cap:

Detach rubber part (1) from hand pump.
Fit special tool 17 0 007 / 17 0 008 .
Screw sealing cap (1) onto special tool.

Build up pressure with special tool (hand pump) 17 0 002 ; observe
pressure gauge to ascertain when opening pressure is achieved.
Compare opening pressure of pressure relief valve.
Check pressure relief valve in sealing cap:
Fit sealing cap (1) on special tool 17 0 007 and connect to vacuum hose
of the vacuum pump.
Sourcing reference: BMW Parts Department.
Supply the vacuum pump with battery voltage.
Slowly apply vacuum to the sealing cap.
Compare opening pressure of the electric changeover valve.
17 00 010 Checking for leaks between cooling system and combustion
chamber
Caution!
Checking for leaks while the engine is running creates the risk of
engine overheating.
Observe coolant temperature.
Check for leaks with CO leak tester.
Follow equipment manufacturer's operating instructions.

17 00 005 Draining and adding coolant (M47, M47TU)
Warning!
Danger of scalding!
Caution!

malfunction.
Recycling
Catch and dispose of drained coolant.
Note:
Follow instructions for working on cooling system,
refer to 17 00 ...
Once the coolant has been added, the cooling system must be
vented and leak-tested,
refer to 17 00 039.
Draining coolant:
Remove cap (1) on expansion tank.

Grip adjusting screw (2) and undo drain plug (1) on radiator at bottom.
Drain, catch and dispose of coolant.
Installation:
Observe Tightening Torque,
refer to 17 11 2AZ.
Undo drain plug (1) on exhaust side of engine block.
Drain, catch and dispose of coolant.
Installation:
refer to 11 11 5AZ.
Adding coolant:
Slacken vent plug (1) on radiator feed.
Release screws (1) and remove acoustic panel (2).
Slacken vent plugs (1/2):

1) Vent plug on EGR cooler thermostat.
2) Vent plug on heating return pipe.
M47 only:
Release vent plug (1) on auxiliary heater.
Air conditioning/air conditioning control

Slacken vent plug (1) on heating feed.
Note:
When adding coolant, it is absolutely essential to adhere to the
following sequence:
1) Remove cap from expansion tank (ET)
2) Open all vent plugs:
Radiator feed - ET branch piece
Coolant return pipe
EGR cooler thermostat
Heating cooler feed
3) Add coolant slowly.

4) Close vent plugs on coolant return pipe and on radiator feed
(ET branch piece) after coolant emerges
5) Fill ET with coolant up to edge
6) Close vent plugs on EGR cooler thermostat and on heating
cooler feed (no emergence of coolant during filling procedure)
7) Start engine (idling), set heater to maximum and fan to low
stage (if necessary, top up coolant to max. fill level)
8) Close ET cap, press accelerator pedal several times up to
approx. 2500 rpm
9) Remove ET cap and if necessary top up coolant to max. cold
fill level
10) Run engine at idle for approx. 5 minutes with open ET (until
bubble-free coolant can be seen to emerge in ET); if required,
top up coolant to max. cold fill level
11) Close ET cap.
Note:
Use only recommended coolant, refer to BMW Service Operating
Fluids in Main Group 17.
17 00 ... Instructions for working on cooling system
Warning!
Risk of scalding, carry out repairs on the cooling system only when
the engine has cooled down.
Attention!
Wear protective gloves and safety goggles.
Attention!
Life-time coolant filling:
Never reuse used coolant!
When replacing and removing components which rely on the
corrosion protection effect of the coolant, it is essential to change
the coolant. The cooling system must therefore be drained and
refilled.
In the case of other removal work involving the draining of part
quantities of coolant, replace these quantities which have been
drained with new coolant.
Installation note:
Use only recommended coolant.
Observe mixture ratio.
Attention!
Open cooling system only when it has cooled down.
Opening the cooling system while hot can result in air entering the
system.
This can cause overheating with permanent damage to the engine.
Attention!
Protect the alternator from contamination when carrying out any
repairs on the coolant circuit.
malfunction.
Attention!
Do not fill coolant expansion tank over maximum level, as overfilling
will cause the coolant to overflow. This may cause traces of coolant
on the expansion tank or in the engine compartment and allow an
incorrect conclusion about possible leaks.
Recycling
Note:
To disconnect the coolant hoses, use a commercially available
disconnection tool such as HAZET (see table).
HAZET number: Description

4590-1 Length of disconnect pliers (mm): 150
4590 / 2 Set of clamping pliers
Set of special tools 17 2 050 for removing and installing the spring
bracket clamps for coolant hoses.
(1) Release tool.
(2) Pliers (bent version).
(3) Pliers (straight version).
Loosen spring strap (1) with the pliers (2).
Unlock spring strap (1) with the release tool (2).

Note:
Tightening torque for hose clamps
WAF 5 1.0 - 1.5 Nm

WAF 6 2.5 - 3.5 Nm
Notes on disassembly/installation of the quick-release couplings of

the coolant hoses
Dismantling of quick-release coupling
Pull out lock (1) and (2). Pull off hose.
Installation note:
Check O-rings (1).
Do not coat O-rings (1) with lubricant.
Assembly of quick-release coupling

Press in lock (1) before installing quick-release coupling.
Push on hose.
Quick-release couplings must clearly snap audibly into place.
17 00 039 Venting cooling system and checking for leaks (M47, M47TU)
Warning!
Danger of scalding!
Caution!

malfunction.
Fill and vent cooling system,

refer to 17 00 005.
Check cooling system for leaks,
refer to 17 00 009.
M47: Note:
To ensure that the cooling system is properly vented, it is
absolutely essential to run through the following steps:
1) Open expansion tank
2) Start engine (idling) and set heater to max. temperature
3) Pour coolant into expansion tank up to max. cold fill level. Run
engine at idle until no further coolant needs to be added.
4) Close expansion tank
5) Scavenge cooling circuit by pressing accelerator pedal twice
(approx. 2000 rpm)
6) Turn off engine and set heater to min. temperature
7) Comply with a waiting time of approx. 3 minutes until auxiliary
water pump in auxiliary heater is no longer running
8) Start engine again without heater
9) Carefully open expansion tank and top up coolant at idle speed
to max. cold fill level
Coolant level check

To check coolant level, allow engine to cool down; coolant temperature
must not exceed 30°C. If ambient temperature is above 30°C, allow
engine to cool down at least to ambient temperature.
Check coolant level, top up coolant if necessary until float (1) is in line
with top edge of expansion tank (2).
Note:
Tank mark indicates the fluid level at approx. 20°C.
Use only recommended coolant,

M47TU: Note:
When adding coolant, it is absolutely essential to adhere to the following
sequence:
1) Remove cap from expansion tank (ET)
2) Open all vent plugs:
Radiator feed - ET branch piece
Coolant return pipe
EGR cooler thermostat
Heating cooler feed
3) Add coolant slowly
4) Close vent plugs on coolant return pipe and on radiator feed (ET
branch piece) after coolant emerges
5) Fill ET with coolant up to edge

6) Close vent plugs on EGR cooler thermostat and on heating cooler
feed (no emergence of coolant during filling procedure)
7) Start engine (idling), set heater to maximum and fan to low stage (if
necessary, top up coolant to max. fill level)
8) Close ET cap, press accelerator pedal several times up to approx.
2500 rpm
9) Remove ET cap and if necessary top up coolant to max. cold fill level
10) Run engine at idle for approx. 5 minutes with open ET (until bubble-
free coolant can be seen to emerge in ET); if required, top up
coolant to max. cold fill level
11) Close ET cap
Note:
Use only recommended coolant, refer to BMW Service Operating Fluids
in Main Group 17.
17 00 009 Checking cooling system for watertightness

17 0 002
17 0 005
17 0 007
17 0 008
Warning!
Risk of scalding!
Checking pressure drop in cooling system:

Remove sealing cap on expansion tank. Fit special tool 17 0 002
/ 17 0 005 .
Build up excess pressure of 1.5 bar, wait approx. 2 minutes.
Cooling system is impervious to leaks if pressure drop is max. 0.1 bar.
Checking pressure relief valve in sealing cap:

Detach rubber part (1) from hand pump.
Fit special tool 17 0 007 / 17 0 008 .
Screw sealing cap (1) onto special tool.

Build up pressure with special tool (hand pump) 17 0 002 ; observe
pressure gauge to ascertain when opening pressure is achieved.
Compare opening pressure of pressure relief valve.
Check pressure relief valve in sealing cap:
Fit sealing cap (1) on special tool 17 0 007 and connect to vacuum hose
of the vacuum pump.
Supply the vacuum pump with battery voltage.
Slowly apply vacuum to the sealing cap.
Compare opening pressure of the electric changeover valve.
17 00 010 Checking for leaks between cooling system and combustion
chamber
Caution!
Checking for leaks while the engine is running creates the risk of
engine overheating.
Observe coolant temperature.
Check for leaks with CO leak tester.
Follow equipment manufacturer's operating instructions.

Attention!
Note:
condenser (2-6).

17 11 509 Flushing radiator
Note: If oil has penetrated the coolant circuit, you must flush the
radiator and coolant expansion tank with cleaning agent, refer to
BMW Service Operating Fluids.
Caution!
When working on the oil, coolant or fuel circuit, protect the alternator
against contamination (not applicable to alternators with coolant
jackets).
malfunction.
Separate coolant expansion tank

Remove radiator.
Remove coolant expansion tank.
Integral coolant expansion tank
Remove radiator.
1. Prepare approx. 2 liters of cleaning agent.

2. Fill radiator and coolant expansion tank and shake well. Wait a few
minutes until oil has separated.
3. Drain radiator and coolant expansion tank.
4. Reinstall cleaned radiator and if necessary coolant expansion tank.
5. Fill entire cooling system (heating control to ”warm”) with hot water
and thoroughly flush by changing water several times.
6. Check drained flushing fluid for traces of oil. If necessary, repeat
Procedure 5.
After cleaning procedure, top up coolant.
Attention!
Note:
condenser (2-6).

17 11 000 Removing and installing radiator (M47)
Warning!
Danger of scalding!
Caution!

malfunction.
Note:
refer to 17 00 ...
Drain off and top up coolant,

refer to 17 00 005.
refer to 17 11 020.
Loosen screws (1).

Intercooler (2) remains in car.
Unlock and disconnect plug connection (1) at needle motion sensor.

Pull retaining clips (1/2) towards top and disconnect coolant hose from
expansion tank/radiator.Installation:
Check O-rings. Do not under any circumstances coat O-rings with
antiseize agent.
Pull retaining clips (1) upwards and disconnect coolant hose from
expansion tank.Installation:
Check O-rings.
Do not under any circumstances coat O-rings with antiseize agent.
Pull retaining clip (1) upwards and disconnect coolant hose from
radiator.Installation:
Check O-rings.
Do not under any circumstances coat O-rings with antiseize agent.
Unscrew bolt (1).

Unscrew bolt (1).
At top, pull out radiator towards rear from fixtures.
17 11 100 Removing and installing/replacing coolant expansion tank (M47)
Warning!
Danger of scalding!
Caution!

malfunction.
Note:
refer to 17 00 ...
Drain coolant from radiator,
refer to 17 00 005.

Withdraw lock (2).
Replace expansion tank:

Unlock coolant level sensor (1) by turning and remove towards bottom
from expansion tank.
Pull lock (1/2) upwards and disconnect coolant hose.
Pull out expansion tank towards rear top from retaining plate and from
lower fitting.Installation:
Check O-rings. Do not under any circumstances coat O-rings with
antiseize agent.
Retaining lug must engage in opening in retaining plate.
17 11 370 Removing and installing/replacing cooling loop for power steering
Warning!
Danger of scalding!
Caution!

malfunction.
Note:
After completing this operation, check fluid level in tank of power steering
system.
Remove and install radiator.
Lever out expansion rivet (1).
Release screw (1).

Pull condenser of A/C system towards rear out of mounts.
Tilt condenser to engine, do not damage condenser in the process.
Note:
Lines of A/C system remain connected to condenser.
Press lines (1/2) in direction of cooling loop and pull black locking ring
towards rear. Keep locking ring pressed and detach lines (1/2) from
cooling loop.
Detach seal (3).
Caution!
Catch and dispose of emerging fluid.
Installation:
Note position of lines. Notch on fast-release coupling must line up with
notch on cooling loop. Fast-release coupling must snap audibly into
place.
Release lock (1). Pull cooling loop of power steering towards rear out of
module carriers.
17 11 020 Removing and installing/replacing radiator shutter (M47, M47TU
with manual transmission)
Caution!
Lift out expansion rivet and remove intake hood (1).
Disconnect charge air hose (1).Caution!

Detach retainer (1) and remove pin from actuating lever.

Close radiator blind (2).
Pull off vacuum hose (3).
Lift out expansion rivet (1).
Release screw (1).

Replace radiator blind.

Loosen screwsÂ (1).
Remove plug (2) from retainer.
Release screw (1) and remove fan cowl (3) from radiator blind (2).
Lift out expansion rivet (1).
Remove vacuum control unit (1) from retainer on radiator blind.

17 32 000 Removing and installing/replacing vacuum control unit for
radiator blind M47
Remove fan cowl,

refer to 17 11 031
Lift out expanding rivet (1).
Remove vacuum control unit (1) from radiator blind.

17 11 031 Replacing fan cowl (M47 / M47TU)

11 5 040
If fitted:
refer to 17 11 020.
M47 and M47TU with manual transmission:

Release screws (1).
Remove plug (2) from retainer.
Release screw (1) and remove fan cowl (3) from radiator blind (2).
Replace fan cowl.

Release screws (1) for clock regulator, release screws (2) for engine.
Pull cable from retainers. Unlock plug (3) and remove from retainer.
refer to 17 40 1AZ, 17 40 2AZ
Note:
Fan is balanced; do not under any circumstances carry fan by fan
impeller.
Failure to comply with this instruction may result in imbalance and
thus fan noise or obstruction.
M47 and M47TU with automatic transmission:
Lever out expansion rivets (1).
Press intake hood (2) towards rear and raise a little.
Pull intake hood (2) out of gaiter (3).

Detach plug from AUC sensor.
Release screw (1).
Lever expansion rivets (1) out of fan cowl.

Caution!
Do not damage radiator fins.
To detach fan wheel (2):
Grip water pump at square drive.
Release union nut (1) with special tool 11 5 040 .
Tightening torque,
refer to Technical Data 11 52 040.
Installation:
When special tool 11 5 040 is used, 30 Nm on the torque wrench
corresponds to a tightening torque of 40 Nm.
Lift out fan cowl and fan wheel together.

Attention!
Note:
condenser (2-6).

Attention!
Note:
condenser (2-6).

17 51 000 Removing and installing/replacing intercooler (M47, M57)
Caution!

Tightening Torque,
Detach charge air hose (2) from intercooler on right.
Caution!

Tightening Torque,
Detach charge air hose (2) from intercooler on left.
Caution!
Press plate (1) forwards, unlock and detach from radiator.

Release screws (1) and pull out intercooler (2) towards bottom.
17 51 000 Removing and installing/replacing intercooler (M47TU, M57TU)

Important!
Coat sealing rings of charge-air hoses with antiseize agent.
Charge-air hoses cannot be fitted without antiseize agent.
Unlock quick-connect couplings (1) and detach charge-air

hoses.Installation:
Charge-air hoses must audibly snap into place.
Press plate (1) forwards, unlock and detach from radiator.
Release screws (1) and pull out intercooler (2) towards bottom.
17 00 ... Instructions for working on cooling system
Warning!
Risk of scalding, carry out repairs on the cooling system only when
the engine has cooled down.
Attention!
Wear protective gloves and safety goggles.
Attention!
Life-time coolant filling:
Never reuse used coolant!
When replacing and removing components which rely on the
corrosion protection effect of the coolant, it is essential to change
the coolant. The cooling system must therefore be drained and
refilled.
In the case of other removal work involving the draining of part
quantities of coolant, replace these quantities which have been
drained with new coolant.
Installation note:
Use only recommended coolant.
Observe mixture ratio.
Attention!
Open cooling system only when it has cooled down.
Opening the cooling system while hot can result in air entering the
system.
This can cause overheating with permanent damage to the engine.
Attention!
Protect the alternator from contamination when carrying out any
repairs on the coolant circuit.
malfunction.
Attention!
Do not fill coolant expansion tank over maximum level, as overfilling
will cause the coolant to overflow. This may cause traces of coolant
on the expansion tank or in the engine compartment and allow an
incorrect conclusion about possible leaks.
Recycling
Note:
To disconnect the coolant hoses, use a commercially available
disconnection tool such as HAZET (see table).
HAZET number: Description

Set of special tools 17 2 050 for removing and installing the spring
bracket clamps for coolant hoses.
(1) Release tool.
(2) Pliers (bent version).
(3) Pliers (straight version).
Loosen spring strap (1) with the pliers (2).
Unlock spring strap (1) with the release tool (2).

Note:
Tightening torque for hose clamps
WAF 5 1.0 - 1.5 Nm

WAF 6 2.5 - 3.5 Nm
Notes on disassembly/installation of the quick-release couplings of

the coolant hoses
Dismantling of quick-release coupling
Pull out lock (1) and (2). Pull off hose.
Installation note:
Check O-rings (1).
Do not coat O-rings (1) with lubricant.
Assembly of quick-release coupling

Press in lock (1) before installing quick-release coupling.
Push on hose.
Quick-release couplings must clearly snap audibly into place.
18 00 020 Removing and installing complete exhaust system (M47, M47TU)
Warning!
Scalding hazard!
Remove splash guard from unit.

Remove front end reinforcement (1),
refer to 31 12 046.
Remove heat shields (2/3).
Release hexagon nuts (1/2) and remove reinforcement (3).

Release hexagon nuts (5) and remove reinforcement (6).
Bracket (4) can remain on transmission.
Release hexagon nuts (1). Detach primary catalytic converter (2)

towards rear from turbocharger.
Check sealing surfaces, clean if necessary.
Installation:
Replace self-locking nuts.
Coat thread with copper paste, refer to BMW Parts Service.
Support exhaust system with lifting equipment.
Release hexagon screws (1/2) and remove reinforcement plates (3/4).
Front rubber mount on rear muffler, release hexagon nuts (1).
Rear rubber mount on rear muffler, release hexagon nuts (1).

Remove complete exhaust system.
18 00 018 Removing and installing rear exhaust system (M47, M47TU without
primary catalytic converter)
Warning!
Scalding hazard!
Release hexagon nuts (1).Installation:

Coat thread with copper paste, refer to BMW Parts Service.
Support exhaust system with lifting equipment.

Release screws (1/2) and remove reinforcement plates (3/4).

Remove complete rear exhaust system.
18 31 040 Removing and installing/replacing primary catalytic converter
(M47, M47TU, M57)

31 2 220
Warning!
Scalding hazard!

Rear drive:
Remove front end reinforcement (1).
Four-wheel drive:
Release screws.
Installation:
Front axle support (1) is lowered approx. 20 mm.
Support right engine support arm with hydraulic lifter and special tool
31 2 220 . Place a block of wood or rubber (1) between right engine
support arm and special tool 31 2 220 .
Release screw connection on engine mount at bottom right.
Raise right engine support arm with hydraulic lifter approx. 2 cm. This
creates enough room to remove the primary catalytic converter.
Rear and four-wheel drives:
Release nuts (1/2) and remove reinforcement (3).
Release nuts (5) and remove reinforcement (6).
Note:
Release nuts (1).

Detach primary catalytic converter (2) towards rear from turbocharger.
Installation:
Check sealing faces, clean if necessary.
Coat threads with copper paste,
Support primary catalytic converter.

Release screw connection (1) and remove primary catalytic converter.
Installation:
18 30 ... Replacing rear muffler bracket on rear axle carrier (repair solution)
Warning!
Scalding hazard!
Only perform these tasks after exhaust system has cooled down.

Detach retaining bar from broken-off bracket of rear axle carrier.
After completing work, check exhaust system for ease of
movement.
Clean bonding surface of rear axle carrier.

Stick on drilling hole template (1) from repair kit as instructed.
Mark bore holes (2) with a centre punch according to template.
Compare centre punch marks with new bracket from repair kit.
Pull off plastic sheet.
Drill bore holes in multiple stages and deburr (e.g. 4, 8, 11 mm dia.).
Finished dia. 11 mm.
Carry out corrosion protection measures.
Install draw-in nuts from repair kit with riveting tongs.
Mount new bracket (1) on rear axle carrier.

Mount retaining bar (2) on bracket (1).
Install suspension (3) (rubber mount).
18 31 040 Removing and installing/replacing primary catalytic converter
(M47, M47TU, M57)

31 2 220
Warning!
Scalding hazard!

Rear drive:
Remove front end reinforcement (1).
Four-wheel drive:
Release screws.
Installation:
Front axle support (1) is lowered approx. 20 mm.
Support right engine support arm with hydraulic lifter and special tool
31 2 220 . Place a block of wood or rubber (1) between right engine
support arm and special tool 31 2 220 .
Release screw connection on engine mount at bottom right.
Raise right engine support arm with hydraulic lifter approx. 2 cm. This
creates enough room to remove the primary catalytic converter.
Rear and four-wheel drives:
Release nuts (1/2) and remove reinforcement (3).
Release nuts (5) and remove reinforcement (6).
Note:
Release nuts (1).

Detach primary catalytic converter (2) towards rear from turbocharger.
Installation:
Support primary catalytic converter.

Release screw connection (1) and remove primary catalytic converter.
Installation:
18 30 ... Replacing rear muffler bracket on rear axle carrier (repair solution)
Warning!
Scalding hazard!
Only perform these tasks after exhaust system has cooled down.

Detach retaining bar from broken-off bracket of rear axle carrier.
After completing work, check exhaust system for ease of
movement.
Clean bonding surface of rear axle carrier.

Stick on drilling hole template (1) from repair kit as instructed.
Mark bore holes (2) with a centre punch according to template.
Compare centre punch marks with new bracket from repair kit.
Pull off plastic sheet.
Drill bore holes in multiple stages and deburr (e.g. 4, 8, 11 mm dia.).
Finished dia. 11 mm.
Carry out corrosion protection measures.
Install draw-in nuts from repair kit with riveting tongs.
Mount new bracket (1) on rear axle carrier.

Mount retaining bar (2) on bracket (1).
Install suspension (3) (rubber mount).
21 00 006 Bleeding clutch hydraulic system

21 5 030

Remove transmission underbody protection if necessary.
If necessary, remove the microfilter housing.
Attention!
Beginning from 08.06 with E8X,E9X clutch slave cylinder plastic
installed.
Important notes on installation are described in this work step.
Unscrew the nuts and remove the clutch slave cylinder (pressure line
remains connected).
Install the special tool 21 5 030 on the clutch slave cylinder (1).
Use the spindle to press the piston rod (2) completely into the clutch
slave cylinder.
Connect bleeder unit to brake fluid expansion tank.Attention!

Check relevant equipment manufacturer's operating instructions for
each device.
Charging pressure should not exceed 2 bar.
Connect vent hose to vent valve (1).
Hold the clutch slave cylinder with the special tool 21 5 030 as shown
(see picture).
Open the vent valve (1).
When bubble-free brake fluid emerges, use the spindle to extend the
piston rod (2) of the clutch slave cylinder slightly and then return it to its
original position.
If no air bubbles emerge, close the vent valve (1); otherwise, repeat the
procedure.
Attention!
Never remove the special tool 21 5 030 from the clutch slave
cylinder when the brake system is under pressure.
The piston with the pressure rod may jump out of the clutch slave
cylinder.
Switch off bleeder unit or remove from brake fluid expansion tank.
Slowly extend the piston rod (2) of the clutch slave cylinder (1) with the
Remove the special tool 21 5 030 from the clutch slave cylinder (1).
Attach the clutch slave cylinder to the transmission.Installation note:

Correct brake fluid level in expansion tank.
21 00 ... Breaking in SAC clutch
Break in SAC clutches moderately to ensure correct operation.
Caution!
Fast sports driving maneuvers destroy new clutches!
Such maneuvers include:
Driving maneuvers with high speed differentials
Overlapping gearshifts with high speed differentials (slipping clutch)
Very high starting speeds (e.g. when driving onto a transporter)
Comply with the following procedure when breaking in the new clutch:
Break in friction linings with light to medium loads (observe breaking-in program)
Normal driving with many ”moderate” gearshifts
Starting speeds on the level up to approx. 2000 rpm
Specific breaking-in program on gentle gradients
Starting speeds on a medium gradient up to approx. 2500 rpm (e.g. when driving onto a transporter)
This procedure helps to create a carbon layer between lining and metal friction surface which generates the
required coefficient of friction.
Breaking-in program:
At approx. 30 km on roads
(specially for M5 and Starting speed max.

Z8) Shift through gears often 2000 rpm
1>2>3>4>5
Upshifts
5>4>3>2>1
Downshifts at 2000 rpm
at 3500-4000 rpm
Upshifts and downshifts
Starting speed max.

3 to 5 times starting on gentle gradient (up to 2500 rpm
approx.
12 %)
Note:
Experience shows that approx. 800 to 1000 gearshifts are required for an optimally broken-in lining
when a car is driven ”normally” (advise customer).
21 21 500 Removing and installing or replacing clutch (SAC 240 /4 cyl.
M47TU/T2 only, 6, 8 cyl.)

11 2 070
11 2 170
21 2 141
21 2 142
21 2 170
21 2 180
21 2 200
21 2 230
Important!
Do not clean self-adjusting clutch and flywheel with high pressure
cleaner or washing machine as the proper function of adjustment
unit and damping springs can no longer be guaranteed.
Clean friction surface only.
Check SAC clutch for wear and damage and replace if necessary.

Note:
Depending on the model, the dual-mass flywheel needs to be replaced in
conjunction with the clutch replacement.
Refer to note in Electronic Parts Catalogue!
Important!
E83 M47/T2:
Before the transmission is removed, the output flange with locking
mass (1) must be removed.
Tightening specifications must be observed!
Operation is described in Replacing shaft seal for front axle
differential drive flange.
Identification SAC clutch dia. 240 mm (Self Adjusting Clutch):
3 openings each with a pressure piece (1) of adjustment ring and a
pressure spring (2)
Note:
Image shows new position of synchronising keys.
4 and 6-cylinder engines:

Lock flywheel (1) with special tool 11 2 170 .
8-cylinder engines:
Lock flywheel with special tool 11 2 070 .
Unfasten bolts and remove SAC clutch from flywheel.Important!

Do not use a special tool to detach SAC clutch from flywheel.
Remove clutch disc (1) from flywheel.
Clean flywheel, check for wear and damage.
Replace damaged flywheel.
Check grooved ball bearing in crankshaft for ease of movement and
tightness and if necessary replace grooved ball bearing.
Important!
Always replace clutch discs fouled e.g. by oil, cleaning agent.
Check clutch disk for damage and friction rust in hub profile and replace if
necessary.
Check clutch disc for wear:

Measure lining protrusion at lining rivets at closing head (A) in each case.
Note:
Rivet connection
A) Closing head
B) Swage head
Replace clutch disc if lining protrusion at closing head (A) is less than
1 mm.
Push clutch disc onto the cleaned transmission input shaft and check for
easy movability.
Important!
Reinstalling removed SAC clutch and clutch disc:

Set SAC clutch (1) down on a clean surface.
Insert special tool 21 2 180 in SAC clutch (1).
Note:
Locking hooks (1) of special tool 21 2 180 must engage in openings of
SAC clutch.
Press special tool 21 2 180 together at handles (1) as far as it will go and
grip firmly.
At same time tighten down knurled screws (2).
Adjustment ring of SAC clutch is now secured in its original position (wear
position).
Important!
Do not reset adjustment ring to new position.
Note:
Fit special tool 21 2 170 only in area of bore holes for dowel pins.
Fit special tool 21 2 170 and tighten down at knurled screw (1).
Screw in spindle (1) until diaphragm spring (2) is tensioned up to stop.
Important!
Handle clutch disk carefully, do not touch surfaces of friction pads.
Install clutch disc in correct position.
Note designation for ”engine side” / ”transmission side”.
Centre clutch disc (1) with special tool.
Special tool Transmission

21 2 141 S6S 420G; S6S 560G; S5D 390Z
21 2 142 S5D 200G; S5D 250G; S5D 260Z; S5D 310Z
21 2 200 GS6-37BZ
21 2 230 GS6-53DZ
Fit SAC clutch (1) on flywheel.

Pay attention to dowel pins (2).
SAC clutch (1) must be secured by way of dowel pins (2).
Insert screws and tighten down.
Release spindle (1) until load is fully removed from diaphragm spring (2).
Release knurled screw (1) and remove special tool 21 2 170 from SAC
clutch.
Release knurled screws (2) and remove special tool 21 2 180 from SAC
clutch.
Withdraw special tool from clutch disc with aid of accompanying screw (1).
Installing removed SAC clutch with new clutch disc:

Important!
Before installing an SAC clutch which has been in service with a new
clutch disc: always reset adjusting ring in new position.
Set SAC clutch down on a clean surface.

Note:
Locking hooks (1) of special tool 21 2 180 must engage in openings of
SAC clutch.
Note:
Screw in spindle (1) until adjusting ring of SAC clutch (2) can be turned
with special tool 21 2 180 at handles (3).
grip firmly.
Adjusting ring of SAC clutch is now secured in new position.
Important!
Note designation for "engine side"/"transmission side".

21 2 141 S6S 420G; S6S 560G; S5D 390Z
21 2 142 S5D 200G; S5D 250G; S5D 260Z; S5D 310Z
21 2 200 GS6-37BZ
21 2 230 GS6-53DZ
Install retaining screws of SAC clutch and tighten down.
clutch.
clutch.
Withdraw special tool from clutch disc with aid of accompanying screw (1).
Installing new SAC clutch:
Important!
Install clutch disc (1) in correct position.
The clutch disengagement module contained in the new AT clutch
set absolutely must be installed.

21 2 141 S6S 420G; S6S 560G; S5D 390Z
21 2 142 S5D 200G; S5D 250G; S5D 260Z; S5D 310Z
21 2 200 GS6-37BZ
21 2 230 GS6-53DZ
Push SAC clutch onto dowel pins (1) located in flywheel and screw down.
Important!
Locking piece (1) may only be removed with SAC
screw-mounted clutch!
Carefully unscrew locking piece (1) clockwise or anticlockwise with a

hexagon socket wrench 14 A/F (2).Note:
A slight snapping of the plate spring while unscrewing is possible.
Withdraw special tool (1) from clutch disc with aid of accompanying
screw (2).
21 21 500 Removing and installing/replacing clutch (SAC 228/4 cyl. without
M47TÜ)

11 2 170
21 2 142
21 2 170
21 2 190
21 2 250
Important!

Remove transmission
Identification SAC clutch dia. 228 mm (Self Adjusting Clutch):

3 recesses each with a synchronising key (1) of adjusting ring and a
compression spring (2)
Note:
The image shows new position of thrust piece.
Lock flywheel (1) with special tool 11 2 170 .

Note:
N45/N46 only!
Lock flywheel with special tool 11 9 260.
Unfasten bolts and remove SAC clutch from flywheel.Important!

Do not use a special tool to detach SAC clutch from flywheel.
Remove clutch disc (1) from flywheel.

Clean flywheel and check for wear and damage.
Replace damaged flywheel.
Check grooved ball bearing in crankshaft for ease of movement and
tightness and if necessary replace grooved ball bearing.
Important!
Always replace clutch discs fouled e.g. by oil, cleaning agent.
Check clutch disk for damage and friction rust in hub profile and replace if
necessary.
Check clutch disc for wear:

Measure lining protrusion at lining rivets at closing head (A) in each case.
Note:
Rivet connection
A) Closing head
B) Swage head
Replace clutch disc if lining protrusion at closing head (A) is less than
1 mm.
Push clutch disc onto the cleaned transmission input shaft and check for
easy movability.
Important!
Reinstalling removed SAC clutch and clutch disc:
Note:
Before installing special tool 21 2 190 in self-adjusting clutch: Adjust
retaining pin to ”A” or ”B”.
A SAC clutch with plastic adjusting ring
B SAC clutch with steel adjusting ring
Pre-adjustment:
Pull out handle (1) and through 180° into position ”A” or ”B”.
Note:
Retaining pins (1) or locking hooks of special tool 21 2 190 must engage
in recesses of self-adjusting clutch.

grip firmly.
Adjusting ring of SAC clutch is now secured in its original position (wear
position).
Important!
Do not reset adjusting ring to new position.
Note:
Important!
Handle clutch disc carefully; do not touch surfaces of friction pads.
Pay attention to text ”engine end” / ”transmission side”.
Centre clutch disc (1) with special tool 21 2 142 .Note:
E46 from 09/03 N40/42/45/46

Insert screws and tighten down.
clutch.
clutch.
Important!
If special tool 21 2 190 cannot be removed from the SAC clutch,
proceed as follows:
Fit special tool 21 2 170 on self-adjusting clutch again and secure

Screw in spindle up to diaphragm spring.
Screw in spindle approx. 1 turn over contact pressure of diaphragm
spring.
Remove special tool 21 2 190 from self-adjusting clutch
Remove special tool 21 2 170 and 21 2 190 from self-adjusting
clutch.
Withdraw special tool 21 2 142 from clutch disc with aid of accompanying
screw (1).Note:
E46 from 09/03 N40/42/45/46
Installing removed SAC clutch with new clutch disc:
Important!
Before installing an SAC clutch which has been in service with a new
clutch disc: always reset adjusting ring in new position.
Note:
Before installing special tool 21 2 190 in self-adjusting clutch: Adjust
retaining pin to ”A” or ”B”.
A SAC clutch with plastic adjusting ring
B SAC clutch with steel adjusting ring
Pre-adjustment:
Pull out handle (1) and through 180° into position ”A” or ”B”.
Note:
Retaining pins (1) or locking hooks of special tool 21 2 190 must engage
in recesses of self-adjusting clutch.

Note:
Screw in spindle (1) until adjusting ring of SAC clutch (2) can be turned
with special tool 21 2 190 at handles (3).
grip firmly.
Adjusting ring of SAC clutch is now secured in new position.
Important!
Handle clutch disc carefully; do not touch surfaces of friction pads.
Pay attention to text ”engine end” / ”transmission side”.
E46 from 09/03 N40/42/45/46

Install mounting bolts of SAC clutch and tighten down.
clutch.
clutch.
Important!
If special tool 21 2 190 cannot be removed from the SAC clutch,
proceed as follows:
Fit special tool 21 2 170 on self-adjusting clutch again and secure

Screw in spindle up to diaphragm spring.
Screw in spindle approx. 1 turn over contact pressure of diaphragm
spring.
Remove special tool 21 2 190 from self-adjusting clutch
Remove special tool 21 2 170 and 21 2 190 from self-adjusting
clutch.
screw (1).Note:
E46 from 09/03 N40/42/45/46
Installing new SAC clutch:
Important!
Install clutch disc (1) in correct position.
The clutch disengagement module contained in the new AT clutch
set absolutely must be installed.
E46 from 09/03 N40/42/45/46
Push SAC clutch onto dowel pins (1) located in flywheel and screw down.
Important!
Locking piece (1) may only be removed with SAC clutch screw-
mounted!
Carefully unscrew locking piece (1) clockwise or anticlockwise with a

hexagon socket wrench 14 A/F (2).Note:
A slight snapping of the plate spring while unscrewing is possible.
screw (1).Note:
E46 from 09/03 N40/42/45/46

21 2 051
21 2 052
Note:
Flywheel removed!
Using hydraulic press (1) and special tool 21 2 051 , press out dual-mass
flywheel downwards on engine side.Important!
Risk of damage:
Roller bearing must not be driven out.
Push roller bearing (2) onto special tool 21 2 052 .

Using hydraulic press (1), press roller bearing into dual-mass flywheel as
far as it will go on clutch side.
Important!
Risk of damage:
Observe press-in instruction:
Roller bearing must not be driven in.
Roller bearing mounting force/travel monitored:
Min. 2000N 1 mm before end of pressing in.
Max. 15000N during entire press-in procedure.
21 51 500 Removing and installing or replacing clutch release bearing/lever
Note: (gearbox removed)
New version (except M models)

Release bearing and release lever have been combined to form a single
release module.
If possible, do not disassemble the release module. Otherwise there is a
risk of the release module being incorrectly reassembled.
Installation note:
Make sure that the correct cam (1) of the release bearing is on the
sliding surface (2) of the release lever.
Note:
Do not grease sliding surfaces (2).
image A: Cam (1) of release bearing (A=12 mm) is on sliding surface of

release lever.
Type: N43, N45, N46
image B: Cam (1) of release bearing (A=7 mm) is on sliding surface of
release lever.
Version for all other engines
Remove release module (1) from spring wire clip.

Remove release module.
Note:
Similar to graphic.
Installation note:
Check wire spring clip (5) and ball pin (6) for damage and replace if
necessary.
Note:
Similar to graphic.
Previous version
Detach release bearing (1).
Installation note:
Clean all sliding surfaces on clutch release bearing, check for
damage and replace if necessary.
Do not grease clutch release bearing.
Sliding surfaces (2) of clutch release bearing must rest on sliding
surfaces (3) of release lever.
Apply a thin coating of grease to sliding surfaces (2) of release
bearing.
Grease, refer to BMW Service Operating Fluids.
Note:
Graphic similar
Important!
Only on E60/E61M5 and E63/E64 M6 (7-gear SMG transmission) -
lightly grease guide sleeve.
Previous clutch release bearing:

Clutch release bearing with moving thrust washer (1).
Swivel motion of thrust washer (1) possible.
Withdraw release lever (4) from wire spring clip (5) and
remove.Installation note:
Clean release lever.
Note:
Similar to graphic.
Previous release leverInstallation note:

Apply a thin coating of grease to release lever at sliding
surfaces (1 and 2) only.
Installation note:
Check spring wire clip (5) and ball pin (6) for damage and replace if
necessary.
Apply a thin coating of grease to ball pin (6).
Note:
The wire spring clip and ball pin must always be replaced on the S6S
420G transmission.
Similar to graphic.
Clean guide sleeve (7).Installation note:

Except for E60/61 M5 and E63/64 M6 (7-gear SMG transmission) - do not
grease guide sleeve.
If guide sleeve is greased, the release lever can stick on the guide
sleeve.
Note:
Similar to graphic.
21 52 510 Removing and installing or replacing clutch slave cylinder

13 3 010
Note:
After completing work bleed clutch hydraulic system.
Important!
From 08.06 a plastic clutch slave cylinder is installed in the E81, E87
and E9X.
Important notes on installation are described in this work step.
Seal supply hose to clutch master cylinder with special tool 13 3 010
.Note:
Illustration shows E46.

Release union screw (1) on hydraulic line.
Release nut (2) and remove hydraulic line (3) with bracket.
Installation:
Note:
Version with throttle valve, tightening torque 21 52 12AZ.
Release nut and remove clutch slave cylinder.Installation:

Important!
N47 with H-transmission only
Clutch slave cylinder must not rest at the side on the transmission.
Failure to comply with this instruction may result in leaks at the
clutch slave cylinder.
Installation:
Clean thrust member (1) and contact face on release lever (2).
Lightly grease thrust member (1) on contact face (3).
Important!
Spacer between fuel line and pressure hose of clutch slave cylinder
must be correctly fitted.
21 52 500 Removing and installing/replacing clutch master cylinder

Remove trim for instrument panel at bottom left
Note:
After completing work, bleed clutch hydraulic system.
Draw off brake fluid up to supply hose of clutch hydraulic system (1). For
this purpose, use only a vacuum pipe that is exclusively used for
removing brake fluid.
Detach supply hose (1) from expansion tank.
Press pin (1) out of clutch pedal with a short, thin screwdriver.
Installation:
The pin is coded by a straight surface (1).
The coding points upwards.
Screw pin with coding upwards. Turn slightly until coding snaps into place.
Press in pin until engaged (2).
Unfasten screws.
Detach retainer (1) with a screwdriver (2).

Note:
Do not soil the footwell carpet with brake fluid.
Detach clutch master cylinder (3) from hydraulic line and remove with
supply hose.
Lever out shift element (1) from clutch master cylinder (2) with
screwdriver.
Release plug connection (3) and disconnect plug (4) from shift
element (1).
Installation:
Shift element is secured against incorrect installation.
Shift element must snap audibly into place.
22 11 011 Replacing left engine mount (M47, M47TU)

00 0 200

If necessary, remove fan cowl.
Release nut (1) on right engine mount.
Release nut (1) on left engine mount.
Raise engine with special tool 00 0 200 ,

described in Removing oil sump.
Tilt engine mount out towards front and remove.
22 11 110 Replacing left engine support arm (M47)
Removing engine support arm is identical to

Removing main flow oil filter.
22 11 110 Replacing left engine support arm (M47TU)
Remove alternator.
Remove left engine mount.
Remove screws (1 and 2).

Remove engine support arm from engine.
Installation:
Screws (1): M8x30
Screws (2): M8x50
22 11 001 Replacing right engine mount (M47, M47TU)

00 0 200


Release screw connection for engine mount at bottom right.
Tilt engine mount out to one side and remove.
22 11 100 Replacing right engine support arm (M43, M47, M47TU, M52)
Remove right engine mount.
Release nut (1), remove grounding cable.Installation:

Clean contact surfaces to ensure a safe ground connection.

22 11 011 Replacing left engine mount (M47, M47TU)

00 0 200


Tilt engine mount out towards front and remove.
22 11 110 Replacing left engine support arm (M47)
Removing engine support arm is identical to

Removing main flow oil filter.
22 11 110 Replacing left engine support arm (M47TU)
Remove alternator.
Remove left engine mount.

Installation:
Screws (1): M8x30
Screws (2): M8x50
22 11 001 Replacing right engine mount (M47, M47TU)

00 0 200


Release screw connection for engine mount at bottom right.
Tilt engine mount out to one side and remove.
22 11 100 Replacing right engine support arm (M43, M47, M47TU, M52)
Remove right engine mount.
Release nut (1), remove grounding cable.Installation:

Clean contact surfaces to ensure a safe ground connection.

Headaches
Dizziness
Stomach aches
Vomiting
Diarrhoea
Cramps/fits
Unconsciousness

or mugs)
First aid measures:

immediately.
23 00 ... Gear train arrangement (S5D 260Z / 310Z / 320Z)
201 Circlip 404 Thrust piece

202 Spacer 405 Ball
203 Input shaft 406 Spring
204 Synchronizer ring 407 Guide sleeve
401 Grooved ball bearing 408 Operating sleeve
402 Circlip 409 Synchronizer ring
403 Spacer 410 Reverse gear
411 Bearing sleeve 416 Spacer

412 Washer 417 Inner race
413 1st gear wheel 418 Intermediate ring
414 Needle bearing 419 Outer race
415 Circlip
404 Thrust piece 421 Operating sleeve

405 Ball 422 2nd gear wheel
406 Spring 423 Needle bearing
417 Inner race 424 Output shaft
418 Intermediate ring 425 Output flange
419 Outer race 426 Collar nut
420 Guide sleeve

302 5th gear wheel 308 Ball
303 Countershaft 309 Spring
304 Needle bearing 310 Guide sleeve
305 3rd gear wheel 311 Operating sleeve
306 Synchronizer ring
306 Synchronizer ring 501 Needle bearing

312 Needle bearing 502 Reverse gear
313 4th gear wheel 503 Thrust washer
314 Thrust washer 504 Reverse gear shaft
315 Washer 505 Half-shell
316 Bolt 506 Bolt
23 00 ... Gearshift component arrangement (S5D 260Z / 310Z / 320Z)
611 Circlip 621 Gate plate

612 Cap 623 Bolt
613 Spring 624 Spring
614 Locking pin 625 Reversing lever
615 Spring 626 Retainer
616 Stop plate 627 Spring
617 Bolt 628 Catch pin
618 Roller 629 Roller
619 Selector arm 630 Shift shaft
620 Spring
601 5th/reverse gear shift arm 606 Shoulder shaft

602 Slide 607 3rd/4th gear shift arm
603 Bearing shaft 608 Cap
604 1st/2nd gear shift arm 609 Spring
605 Locking lever 610 Catch pin
23 00 ... Housing arrangement, front/rear section (S5D 260Z / 310Z / 320Z)
101 Front case section 115 Plain bearing

102 Guide tube 116 Sleeves
103 Radial sealing ring 117 Plate
104 Bolts 118 Needle bearing
105 Dowel pin 119 Ball bearing
106 Plug 120 Magnet
107 Plain bearing 121 Rear case section
108 Plain bearing 122 Cap
109 Shaft 123 Sleeve
110 Plug 124 Ball sleeve
111 Ball bearing 125 Radial sealing ring
112 Element 126 Bolts
113 Bolts 127 Radial sealing ring
114 Ball bearing 128 Cover
23 00 034 Installing replacement transmission (GS5-39DZ)
Note:
After completion of work, check transmission oil level.
Important!
Use only the approved gear oil in this manual transmission.

the manual transmission.
Drain off gear oil from old transmission.

Catch and dispose of emerging gear oil.
Recycling:
Convert following components of old transmission to new transmission:

Release bearing and release lever.
Threaded pin for slave cylinder.
Reversing light switch.
Convert shift rod joint.

Push retaining ring (1) back and drive out straight pin (2).
Installation:
Check damping disk (6) in joint for damage.
Replace damping disk (6) in joint if necessary.
Detach breather (1) and protective sleeve (2) from selector shaft.
Lever out sealing flap (3) and breather (1).
23 00 036 Installing replacement transmission (GS6-37BZ/DZ)
Important!
After completion of work, check transmission oil level .
Use only the approved transmission oil .
Failure to comply with this instruction will result in serious damage to the
transmission.
Recycling:
Catch and dispose of escaping transmission fluid.

Drain gear oil at oil drain plug. Tightening torque: 23 00 4AZ
Remove transmission
Convert following parts from previous transmission to new transmission.

Release bearing and release lever .
Ball pin and spring wire clip.
Studs for clutch slave cylinder.
Reversing light switch tightening torque: 23 41 5AZ .
Release screws.
Remove and convert transmission bearing block.
Tightening torque 23 71 3AZ/4AZ .
Note:
Graphics show E60.

Push back retaining ring (1) and drive out dowel pin (2).
Note:
Check damping disc (6) for damage and replace if necessary.

Check oil level.
Installation:
Observe greasing specification .
23 00 033 Installing replacement transmission (S5D 310Z / S5D 320Z)
Fit following parts from old transmission on the new transmission:

- Release bearing and release lever
- Dowel pin for slave cylinder
- Reversing light switch

Push retaining ring (1) back and drive out straight pin (2).
Installation:
Check damping disk (6) in joint for damage and replace if necessary.
Detach breather (1) and protective sleeve (2) from selector shaft.
Lever out sealing flap (3) and breather (1).
00 11 229 Oil change in manual transmission
Note:
Gearbox must be at normal operating temperature.
Gear oil:
Filling capacities:
Draining gear oil:

Release oil drain plug (1) and filler plug (2).
Clean oil drain plug (1) and screw in.
Fill transmission with ATF.
Pour in gear oil until overflowing.
Tighten in filler screw (2).
23 00 024 Removing and installing transmission (GS5-39DZ, M47TU / M57)

00 2 030
23 0 140
Note:
Important!

Disconnect battery.
M47TU:
Open cable duct (1) and remove cable.
Detach gaiter (2) from intake hood.
E46 Compact:
Important!
The section ”Removing and installing reinforcement plate” contains
important installation instructions.

M47TU:
Remove heat shield (1).
Release screws (1).

Remove exhaust suspension (2).
Support transmission with special tools 23 0 140 and 00 2 030 .

Release screws and remove cross-member.
Tightening torque 23 71 1AZ / 2AZ.
Release screws.
Installation:
When tightening screws down: Grip each screw and tighten down
nut. This prevents the propeller shaft from being subjected to
torsion stress.
Important!
Do not let propeller shaft fall into joints.
Joints and rubber sleeve can be damaged on constant-velocity joint.
Grip propeller shaft and release screws.

Bend propeller shaft downwards at center bearing (1).
Detach propeller shaft from transmission output flange and tie back to
side on vehicle underbody.
Installation:
Center bearing must be aligned at right angles to propeller shaft.
Note on installation (except E46 Compact):
Pull off cover tape from butylene tape on both sides.
Stick butylene tape (1) to outside of center bearing (2).
Butylene tape,
Important!
Remove butylene tape already attached to center bearing.
Clean adhesive area on center bearing and on body.
Then coat adhesive area on body with mineral oil.
This coating with oil is necessary to facilitate insertion of the sticky
butylene tape in the propeller shaft tunnel.
This prevents the butylene tape from being deformed.
Installation:
Press center bearing (2) into transmission tunnel.
Lift out retainer (1).

Disconnect shift rod (2).
Installation:
Grease selector rod.
Grease,
Pay attention to position of shims (3).
M47TU:
Suspend special tool 11 8 022 from left and right control arms.
Lower transmission until cylinder head touches bulkhead.
Important!
Position special tool so that engine oil sump is securely resting on
special tool.
Tighten down knurled screws until special tool rests against engine oil
sump.
M57:
Secure engine at front in removal position with hydraulic lifter 00 2 030 .
Note:
Pressure line of clutch slave cylinder remains connected.
Important!
Slowly relieve tension on clutch slave cylinder as otherwise air will
be taken in through sealing sleeve.
Release nuts and remove clutch slave cylinder.

Release and lever out bearing pin (1) with a screwdriver.
Remove bearing pin (1).

Lever out selector arm (1).Installation:
Grease bearing pin (1).
Grease,
Release screw (1).
Detach cable plug (1) from reverse gear switch.

Detach cables from fixtures.
Warning!
Danger of pinching!
If the engine is inadequately positioned, it rests on the stabilizer.
Unfasten screws.
Important!
Do not allow the transmission to hang off from the transmission
input shaft as this will deform the clutch plate.
Pull out transmission towards rear and remove.

Installation:
Pay attention to guide sleeves (1 ... 2), replace if necessary.
Ensure correct position of cover plate.
Installation:
Remove release unit and release lever, clean and apply grease to
relevant points.
Installation:
Check lubrication of transmission input shaft for sticky consistency.
If grease is sticky, replace clutch plate.
Check clutch plate for friction rust in taper splines and replace if
necessary.
Refer to 21 21 500.
Mechanically remove old grease and lining abrasion from the taper
splines of the clutch disc (with a cloth).
Then, using a brush, apply a thin, even coat of grease over entire
area of taper splines, taper groove and guide pin.
Grease,
23 00 019 Removing and installing transmission (GS6-37BZ/DZ)

00 2 030
21 2 220
23 0 131
23 0 132
23 0 134
Important!
Use only the approved transmission oil.

the manual gearbox.

Clamp off battery.
Remove heater end panel.
Remove engine guard.
Remove exhaust system (M54 only).
Remove exhaust system without primary catalytic converter
(M47TU only).
Installation note:
Important notes on installation are described in the job item
"Reinforcement plate".

Release screws (1) and (2).

Loosen screws (1) and turn primary catalytic converter (2) to the side.
Detach connector (1) from reversing light switch.

Release cable from brackets.
Release bolts and remove exhaust bracket.
Supporting transmission:
Support with special tools 23 0 134 , 23 0 131 , 23 0 132 and 00 2 030 .
Release screws (1) and nuts (2) and remove cross member.
Tightening torque 23 71 2AZ/5AZ.
Note:
Graphics show E60.
Remove propeller shaft from transmission.

Release centre mount.
Important:
Bending the propeller shaft by an excessive angle can cause
premature damage to the joint/propeller shaft!
Tie up propeller shaft to underbody.
Support engine with lifter when removing transmission.
Lever out retainer (1).
Disengage gearshift rod (2).
Installation note:
Grease gearshift rod.
Grease,
Make sure shims (3) are in correct position.
Release and remove bearing journals (1) in direction of arrow.
Lift out gearshift arm (1).Installation note:

Grease bearing journals (1).
Grease,
Note:
Pressure line of clutch slave cylinder remains connected.
Important!
Slowly relieve tension on clutch slave cylinder otherwise air is drawn
in through sealing cup.

Release screw (1).
Release screws.
Important!
drive shaft as this will deform the clutch disc. Pull out transmission
towards rear and remove.
Installation note:
Check that fitting sleeves are correctly fitted.
Replace damaged fitting sleeves.
Installation note:
Check lubrication of transmission drive shaft for sticky consistency. If
grease is sticky, clean drive shaft and replace clutch disc.
Check clutch disc for friction rust in gearing and replace if necessary.
Mechanically remove existing grease and lining abrasion from gearing of
clutch disc (with a cloth).
Installation note:
Greasing specification:
Remove and clean release bearing and release lever.
Push on grease scraper ring 21 2 220 until limit position.
Grease teeth (1) of input shaft. Refer to BMW Service Operating
Fluids.
Detach grease scraper ring.
23 00 023 Removing and installing transmission (S5D 320Z, M47)

11 8 022
Note:
Caution!

the transmission.
Disconnect battery.

Caution!
The section "Removing and installing reinforcement plate" contains

Support transmission with a workshop hoist.

Release screws and remove cross-member (1).
Tightening torque, 23 71 1AZ / 2AZ.
Release screws.
Installation:
Grip propeller shaft and release screws on front center bearing (1).
Release nuts on center bearing (1).

Bend propeller shaft downwards at center bearing.
Installation:
The deflection angle of the rear propeller shaft was adjusted in
series-production assembly with the aid of washers (1).
The washers (1) are marked in the center with a colored plastic
insert and secured to the threaded pins.
When installing propeller shaft, make sure the same washers (1)
are fitted again.
Caution!
Pressure line remains connected.
Slowly relieve tension on clutch slave cylinder during removal as
otherwise air will be drawn in through sealing sleeve.

Detach retaining clip (1).
Pull shift rod (1) out of shift lever (2).

Remove washers (3).
Installation:
Grease shift rod pin (4).
Grease,
Large contact surface of disks (3) must rest on shift rod joint (2).
Lever out spring (1) with a screwdriver from lug (2) on housing.
Tilt spring (1) upwards.
Remove bearing pin (1).Installation:

Grease,
Detach cable plug (1) from reverse gear switch.
Detach cable from fixtures.
Attach special tool 11 8 022 to left and right control arms.

Caution!
Position special tool so that engine oil sump is securely resting on
special tool.
Tighten down knurled screws until special tool rests against engine oil
sump.

Release screws.
Caution!
input shaft as this will deform the clutch plate.
Pull out transmission towards rear and remove.
Installation:
Pay attention to guide sleeves (1 ... 2), replace if necessary.
Installation:
Remove release unit and release lever, clean and apply grease to
relevant points.
Installation:
Check lubrication of transmission input shaft for sticky consistency.
If grease is sticky, replace clutch plate.
Check clutch plate for friction rust in taper splines and replace if
necessary.
Mechanically remove old grease and lining abrasion from the taper
splines of the clutch disc (with a cloth).
Then apply a thin and even coat of grease with a brush in entire
area of taper groove.
Grease,
Danger of injury!
Impaired sight

First aid measures:

Warning!
Recycling:

ground.
23 00 ... Transmission arrangement (S5D 260Z / 310Z / 320Z)
1 Gear wheel 1st gear 4 Gear wheel 4th gear

2 Gear wheel 2nd gear 5 Gear wheel 5th gear
3 Gear wheel 3rd gear R Gear wheel, reverse gear


23 00 ... Transmission arrangement, front section (S5D 260Z / 310Z / 320Z)
101 Front case section 109 Shaft

102 Guide tube 110 Plug
103 Radial sealing ring 111 Ball bearing
104 Bolts 112 Element
105 Dowel pin 113 Bolts
106 Plug 114 Plain bearing
107 Plain bearing 115 Needle bearing
108 Plain bearing
23 00 ... Transmission arrangement, rear section (S5D 260Z / 310Z / 320Z)
116 Sleeves 123 Sleeve

117 Plate 124 Ball sleeve
118 Ball bearing 125 Radial sealing ring
119 Ball bearing 126 Bolts
120 Magnet 127 Radial sealing ring
121 Rear case section 128 Cover
122 Cap
23 Transmission designations
Breakdown of BMW designation:
A5S 300J (former designation)

A Transmission type
S = Manual gearbox
A = Automatic transmission
5 Number of forward gears

S Type of top gear
D = Direct gear
S = Overdrive gear
300 Max. input torque (Nm)

J Code letter of transmission manufacturer
G = Getrag
J = Jatco
R = GMPT (General Motors Powertrain)
Z = ZF (Zahnradfabrik Friedrichshafen)
SMG Notes SMG = Sequential M gearbox/transmission
GS6-37BZ (new designation according to BMW Group Standard GS 90007)

G Transmission
S Transmission type
S = Manual gearbox

-
- = Standard with manual gearshift
HP = Hydraulic planetary gear
DKG= twin-clutch gearbox
37 Transmission type
26 = D-transmission
31 = C-transmission
39 = F-transmission
37 = H-transmission
53 = G-transmission
17 = I-transmission
47= J transmission SMG -7-speed
45 = K transmission
36= Transmission DKG
B Gear set
B = Petrol gear ratio
D = Diesel gear ratio
S= Sport gear ratio
Z Code letter of transmission manufacturer
G = Getrag
A = AISIN
Manual gearbox:
BMW designation Manufacturer Manufacturer designation Remarks
S5D 200G Getrag B transmission (220/5)

S5D 200G Getrag B transmission (221/5) for M41 engine only
S5D 250G Getrag B transmission (220/5) Reinforced version
S5D 260Z ZF C-transmission (S5-31 D) for M51 engine only

S5D 280Z ZF C-transmission (S5-31)
S5D 310Z ZF C-transmission (S5-31) up to 9.95
S5D 320Z ZF C-transmission (S5-31) from 9.95 (reinforced version)
GS5S31BZ (SMG) ZF C transmission SMG
GS5-39DZ ZF F transmission
S6S 420G Getrag D-transmission (226/6)
S6S 420G (SMG) Getrag D transmission SMG
S6S 560G Getrag E-transmission (286/6)
GS6-37BZ ZF H-transmission
GS6S37BZ (SMG) ZF H-transmission
GS6-37DZ ZF H-transmission
GS6-37BG Getrag H-transmission
GS6-53BZ ZF G-transmission
GS6-53DZ ZF G-transmission
GS6-17BG Getrag I-transmission

GS6-17DG Getrag I-transmission
GS7S47BG (SMG) Getrag J‐transmission (247) SMG -7-gear
GS7D36SG Getrag DKG (436) DKG -7-gear
GS6- 45BZ ZF K transmission

GS6- 45DZ ZF K transmission
GS6-60DA/BA AISIN BG6

7DCT300 Getrag 7DCT DKG -7-gear
GS6-58DG/BG Getrag
GS6-59DG/BG Getrag
Automatic transmission:
A4S 200R General Motors Powertrain GM4
A4S 270R General Motors Powertrain THM-R1w Transmission wide-stepped

A4S 310R General Motors Powertrain THM-R1
A5S 300J Jatco Jatco
A5S 310Z ZF 5HP-18

A5S 325Z ZF 5HP-19
A5S 440Z ZF 5HP-24
A5S 560Z ZF 5HP-30
A5S 360R / 390R GM GM5
GA6F21AW AISIN GA6F21AW

GA6HP19Z ZF 6HP19
GA6HP26Z ZF 6HP26
GA6HP32Z ZF 6HP32
GA6L45R GM GM6

GA8G45 AISIN 8G45
GA8HP45Z ZF 8HP45
GA8HP50Z ZF 8HP50
GA8HP51Z ZF 8HP51
GA8HP70Z ZF 8HP70
GA8HP75Z ZF 8HP75
GA8HP76Z ZF 8HP76
GA8P70H ZF 8P70 Hybrid
GA8HP90Z ZF 8HP90
GA8HP95Z ZF 8HP95
GA7AHSCD Daimler AHS-C Hybrid
23 ... Universal BMW transmission take-up

00 2 030
23 4 050
Note:
The universal transmission bracket is introduced for the E60 AWD
Suitable for manual and automatic transmissions
Important!
Front and rear supports (1) can be laterally adjusted by means of
screws (2).
Carrier (3) of rear supports (1) can be longitudinally adjusted by
means of screw.
Supports must be adapted in length and width to the transmission.
Support transmission with special tools 23 4 050 , 00 2 030 .
Important!
Transmission must be secured with tensioning strap (1).
23 Universal transmission retaining bridge

0 495 187
24 0 200
Note:
Transmission retaining bridge 24 0 200 is suitable for manual and
automatic transmissions
Attention!
The adapter and shaft must be adapted to positively lock with the
transmission.
(Danger of injury)
Adapt the adapter (1) and spindle with the thrust piece (3) on the
transmission.
Adjust the length using the sliding piece (2).
Screw in spindle (4).
Attention!
Before mounting on assembly stand0 495 187 check retraining
bridge for tight fit.
23 11 565 Replacing bearing bushing for 5th/reverse gear locking pin (C/F
transmission) - transmission removed

00 1 450
23 0 170
23 4 021
23 4 022
23 4 023
Place transmission (1) with special tool 23 0 170 in assembly stand

00 1 450 .
Note:
1=Locking pin for reverse gear
2=Locking pin for 5th gear
Release retaining ring (1).

Drive sealing cap (2) out of transmission housing with a suitable tool.
Important!
Bore hold must not be damaged. A burr or a dent can cause the
sealing cap to leak.
Installation:
Replacing sealing cap (2).
Note:
Illustration shows: Sealing cap for reverse gear
Remove pressure spring and locking pin.Important!
Pressure spring and locking pin for reverse and 5th gears must not
be mixed up.
5th gear locking pin Reverse gear locking pin

Curved slant Straight slant
Weaker pressure spring Stronger pressure spring
Installation:
Reverse gear locking pin:
Slant must point downwards in bell housing in direction of travel!
5th gear locking pin:
Slant must point upwards in bell housing in direction of travel!
Note:
Illustration shows: 5th gear pressure spring!
Force open bearing bushing (1) and withdraw using a suitable

tool.Important!
Force open bearing bushing (1) at specified indent (2) only.
Bore hold must not be damaged!
Drive in bearing bushing (1) with special tool (see table) as far as it will
go.Important!
Make sure you use the correct special tool, as the different tools
have different dimensions!
5th gear 23 4 022 (short)

Reverse gear 23 4 023 (long)
Drive in sealing cap (1) with special tool 23 4 021 .

Fit retaining ring.
23 30 ... Replacing catch pin (S5D ...Z and GS5-39DZ / C- and F-
transmissions)

00 1 450
23 0 170
23 0 490
23 2 360
23 3 110

Remove gearbox

00 1 450 .
Stamp a small hole into sealing cover (e.g. with scribing tool).
Screw special tool 23 0 490 into sealing cover.
Drive out sealing cover upwards.
Caution!
Do not damage edge of bore hole in transmission housing. A burr or
a dent may cause the sealing cover to leak.
Lift pressure spring and sleeve out of transmission housing with
magnet (1) or grippers.
Installation:
Following new components must be fitted in succession:
1. Collared bushing
2. Stop pin
3. Spring
4. Cap
Caution!
It must be possible to drive in the collared bushing without the
exertion of great effort.
Anodized layer of collared bushing must not be damaged.
Screw in collared bushing (1) partially with slot (S) counterclockwise (90°
to direction of travel).
Drive collared bushing with special tool 23 3 110 and plastic hammer into
transmission housing as far as it will go.
Insert stop pin (2) and pressure spring (3) in collared bushing.
Drive sealing cover (7) with special tool 23 2 360 into transmission
housing as far as it will go.Note:
Repeat task with the catch pins (5 and 6) of the other gears.
23 11 611 Replacing guide tube for clutch release gear (S5D 310Z/ S5D 320Z)
Remove clutch release bearing and release lever from guide tube.
Release screws.
Remove guide tube (1).
Note:
Remove all traces of sticker (1) with a suitable solvent.
23 11 613 Replacing guide tube for clutch release unit (GS5-39DZ)
Remove clutch release stop and release lever.
Release screws.
Note:
Remove all traces of sticker (1) with a suitable solvent.
23 12 505 Replacing drive shaft radial seal (S5D 260Z/ 310Z/ S5D 320Z)

23 0 490
23 2 340
23 2 380
Note:
Caution!

the transmission.
Transmission removed.
Remove release unit and release lever.
Unfasten screws and remove guide tube.

Note:
Two covered removal holes (1) are located on the end face of the
radial sealing ring.
Screw special tool 23 0 490 into one of two removal holes.
Pull radial sealing ring out of transmission housing with impact weight.
Fit special tool 23 2 380 onto transmission input shaft.

Coat sealing lips of new radial seal (1) with transmission oil and slide
firmly home on transmission case.
Remove special tool 23 2 380 from drive shaft.
Drive radial seal (1) firmly home with special tool 23 2 340 .Note:
To drive in: use a plastic hammer.
23 12 055 Replacing output flange radial seal (S5D 260Z/ 310Z/ S5D 320Z)

00 5 010
23 0 020
23 2 300
23 2 320
33 1 150
Note:
Caution!

the transmission.
Unflange propeller shaft from transmission and tie up to one side.

Unfasten screws and remove cross-member.
Installation:
Brace output flange with special tool 23 0 020 .

Release collar nut (1) with special tool 23 2 320 .
Installation:
Install collar nut (1) with screw retaining compound; for compound,
Detach output flange with special tool 33 1 150 from output
shaft.Installation:
Heat output flange to approx. 80°C and push onto output shaft.
Remove radial seal with special tool 00 5 010 .
Coat sealing lips of new radial seal (3) with transmission oil.
Drive radial seal (3) home flush with special tool 23 2 300 .
Note:
23 12 507 Replacing radial seal for drive shaft (GS5-39DZ)

00 1 450
23 0 170
23 0 181
23 0 182
23 0 490
23 2 491
Note:
Important!

Secure transmission (1) with special tool 23 0 170 to assembly stand

00 1 450 .
Remove release unit and release lever.

Release screws and remove guide tube.
Note:
Replace screws.
Installation:
Replace gasket (1).
Clean sealing face.
Note:
Two covered removal holes (1) are located on the end face of the
radial sealing ring.
Screw special tool 23 0 490 into one of the two removal holes.
Withdraw radial seal from transmission housing with aid of impact weight.
Attach special tool 23 0 182 to transmission input shaft.
Coat sealing lips of new radial seal (1) with gear oil and push on up to
transmission housing.
Remove special tool 23 0 182 from transmission input shaft.
Drive in radial seal with special tools 23 0 181 and 23 2 491 as far as it will
go.Note:
23 12 058 Replacing radial seal for output flange (GS5-39DZ)

00 5 010
23 0 020
23 0 190
23 0 200
Important!
Use only approved transmission oil.
Failure to comply with this instruction will result in serious damage to
the transmission.

Remove rear underbody protection
Remove and install exhaust system

E39:
Unscrew screws (1).
Remove reinforcement carrier (2)
Unflange propeller shaft from transmission and tie up to one side.

Unfasten screws and remove cross member.

Installation:
Insert collar nut (1) with Loctite 243.
Loctite 243: BMW Parts Service.
Detach output flange with 3-claw extractor from output shaft.Installation:

Heat output flange to approx. 80°C and push onto output shaft.
Remove radial seal with special tool 00 5 010 .
Coat sealing lips of new radial seal (1) with transmission oil.
Drive in radial seal (1) with special tool 23 0 190 and plastic hammer until
flush.
23 12 080 Replacing radial seal for selector shaft (GS5-39DZ)

23 0 210
23 0 220
Note:
Important!

Shift transmission into 2nd gear.

Remove rear underbody protection.
Remove exhaust system.

E39:
Release screws (1).
Remove reinforcement carrier (2).
Remove propeller shaft from transmission.

Tie back propeller shaft to one side.

Push retaining ring (1) away and drive out straight pin (2).
Unhook selector rod.
Screw in special tool 23 0 210 until it is firmly connected to radial seal (1).
Pull out radial seal by screwing in screw on special tool.
Drive in radial seal with special tool 23 0 220 .

23 12 085 Replacing radial seal for selector shaft (S5D 260Z / 310Z / 320Z)

23 0 210
23 0 220
Note:
Caution!

the transmission.

Unflange propeller shaft from transmission and tie back to one side.
Lever retaining ring (1) out of groove with a small screwdriver.

Push retaining ring (1) towards rear.
Drive out straight pin (2).
Screw in special tool 23 0 210 until it is firmly connected to radial seal (1).
Pull out radial seal with special tool 23 0 210 .
Coat sealing lips of radial seal and selector shaft with gear oil.
23 12 508 Replacing radial shaft seal for drive shaft (GS6-37BZ/DZ)

23 3 151
23 3 152
Important!
After completion of work, check transmission oil level .
Use only approved transmission oil .
Failure to comply with this requirement will result in serious damage
to the automatic transmission!

Remove transmission .
Remove clutch release unit and release lever from guide tube.
Release screws.
Tightening torque: 23 11 2AZ .
Installation:
Clean guide tube.
Do not grease guide tube.
Release screw on special tool 23 3 151 .

Push special tool onto drive shaft and screw into sealing ring.
Insert screw into special tool 23 3 151 again and continue turning until
sealing ring is pulled out of transmission housing.
Installation:
Coat sealing lips of radial seal with gear oil.
Push radial seal (1) onto drive shaft up to housing.
Drive in radial shaft seal (1) as far as it will go with special tool 23 3 152
and plastic hammer.
23 12 050 Replacing radial shaft seal for output flange (GS6-37BZ/DZ H-
gearbox)

23 0 020
23 2 320
23 3 161
23 3 162
33 1 150
Attention!
Use only approved gearbox oil.
the transmission.

Remove exhaust system
Support transmission
Remove transmission cross-member
Remove transmission bearing block
Unflange propeller shaft from transmission and tie to one side

Release collar nut with special tool 23 2 320 .
Installation note:
Mark flange with thermo crayon and heat to min. 100 °C.
Warning!
Risk of burning! Fit flange wearing suitable protective gloves only!
Attention!
Do not drive on flange.
Secure collar nut with Loctite 243.

Loctite 243: BMW Parts Department.
Detach output flange with special tool 33 1 150 from output shaft.
Release screw on special tool 23 3 161 .

Push special tool over output shaft and screw firmly into sealing ring.
Insert screw into special tool again and continue turning until sealing ring
is pulled out of transmission housing.
If necessary, remove Woodruff key of sealing ring.
Installation note:
Coat sealing lips of new radial shaft seal with transmission oil.
Drive in radial shaft seal to limit position with special tool 23 3 162 and
plastic hammer.
23 12 088 Replacing radial shaft seal for selector shaft (GS6-37BZ/DZ H-
transmission)

23 0 210
23 0 220
Important!
After completion of work, check gear oil level.
Use only approved transmission fluid.
the transmission.

Shift transmission into 2nd gear
Unflange propeller shaft from transmission and tie up to one side
Lever retaining ring (1) out of groove with a small screwdriver.

Slide locking ring (1) towards rear.
Drive out cylinder pin (2).
Screw in special tool 23 0 210 until it is firmly connected with radial

seal (1).
Pull out radial seal with special tool 23 0 210 .
Coat sealing lips of radial seal and selector shaft with gear oil.

202 Spacer 405 Ball
203 Input shaft 406 Spring
204 Synchronizer ring 407 Guide sleeve
401 Grooved ball bearing 408 Operating sleeve
402 Circlip 409 Synchronizer ring
403 Spacer 410 Reverse gear
411 Bearing sleeve 416 Spacer

412 Washer 417 Inner race
413 1st gear wheel 418 Intermediate ring
414 Needle bearing 419 Outer race
415 Circlip
404 Thrust piece 421 Operating sleeve

405 Ball 422 2nd gear wheel
406 Spring 423 Needle bearing
417 Inner race 424 Output shaft
418 Intermediate ring 425 Output flange
419 Outer race 426 Collar nut
420 Guide sleeve

302 5th gear wheel 308 Ball
303 Countershaft 309 Spring
304 Needle bearing 310 Guide sleeve
305 3rd gear wheel 311 Operating sleeve
306 Synchronizer ring
306 Synchronizer ring 501 Needle bearing

312 Needle bearing 502 Reverse gear
313 4th gear wheel 503 Thrust washer
314 Thrust washer 504 Reverse gear shaft
315 Washer 505 Half-shell
316 Bolt 506 Bolt
23 21 502 Removing and installing complete drive and output shafts (S5D
260Z / 310Z / 320Z)

00 1 490
23 0 020
23 0 100
23 0 490
23 1 050
23 1 160
23 2 150
23 2 250
23 2 260
23 2 270
23 2 280
23 2 290
23 2 293
23 2 300
23 2 320
23 2 330
23 2 340
23 2 350
23 2 360
23 2 370
23 2 380
33 1 150
33 1 301
Remove clutch release unit/lever.
Unscrew drain plug.
Drain off oil.
Screw special tool 23 0 100 (transmission bracket) into hole for drain plug
and secure.
Mount special tool 23 0 100 on assembly stand 00 1 490 .
Recycling:
Release screws and pull out guide tube.
Note:
Two covered removal holes (1) are located on end face of radial
seal.
Screw special tool 23 0 490 into one of the two removal holes.
Withdraw radial seal from transmission housing with aid of impact weight.
Remove left bearing pin and screw for reverse gear pin in front housing
section.
Remove reverse gear switch and right bearing pin in front housing
section.
Lever out retaining ring (1).

Remove sealing cover (2).
Remove pressure spring (3) and catch pin (4).

Remove housing screws.
Pull off front housing section with special tools 23 2 280 and 33 1 301 .
Caution!
Bearings or elements of the bearing brackets could be damaged
while pulling off the front case section.
Catch pin for 5th/reverse gear falls out.
Always replace bearings and segments during removal.
Remove pressure spring (1) and thrust pin (2).

Remove roller bearing (3).
Withdraw shift shaft (4).

Caution!
Needles on shift shaft.
Remove 5th/reverse gear shift arm towards top.

Remove 2 bearing pins on right.Note:
Remove 3 bearing pins on left.Note:

Remove locking lever (1) completely.

Remove pressure spring (2) and thrust pin (3).
Remove screw (4).

Remove reverse gear wheel with needle bearings, thrust washer, pin and
half shell.
Pierce sealing cover (5) on side.
Lever out sealing cover (5) in hole with a screwdriver.
Installation:
Replace sealing cover.
Engage a gear by hand.

Grip output flange with special tool 23 0 020 .
Release screw (6).
Caution!
Left-hand threads.
Remove washer (7).

Disengage selected gear again.

Detach output flange with special tool 33 1 150 .

Compress gear train at 5th/reverse gear sliding sleeve with countershaft
with special tool 23 2 250.
Attach special tool 23 2 370 to output shaft and countershaft.

Attach special tool 23 1 050 to housing sealing surface and center of
Caution!
Use a piece of wood, plastic or similar on the sealing surfaces.
Press out gear train and countershaft uniformly.

When pressing out, make sure gear train and countershaft do not get
jammed.
Installation:
The bearings or elements of the bearing brackets could be
damaged while pressing out the drive and output shafts.
Always replace bearing and segments during removal.
Remove gear train with 1st/2nd and 3rd/4th gear shift arms and
countershaft.
Installation:
Clean housing.
Drive out sealing cap (1 and 2) on rear housing section with a mandrel
from inside to outside.
Installation:
Replace sealing cap.
Replace bearing (1) and (2) (output shaft, countershaft and retaining
plates).
Lever out radial seal (3 and 4) for output and selector shafts.
Compress gear train at 5th/reverse gear sliding sleeve with countershaft.

Use special tool 23 2 250 .
Attach 3rd/4th gear shift arm with sliding blocks to 3rd/4th gear slide
sleeve.
Rest shift arm on 3rd gear wheel of output shaft.
Connect shift arm with catch (1) in direction of drive shaft on left.
Insert gear train with shift arm in rear housing section.

Attach 1st/2nd gear shift arm with sliding blocks to 1st/2nd gear slide
sleeve.
Caution!
Connect shift arm with catch (1) in direction of drive shaft on left.
Attach special tool 23 2 330 to output shaft journal. Draw in output shaft
with special tool 23 2 330 until firmly seated.
When drawing in, make sure shift arms and countershaft do not get
jammed, align if necessary.
Center 3rd/4th gear shift arm by hand with bore in housing. In this
position, screw in bearing pins (2) in succession on left and right and then
tighten down.
Oil sealing lip of radial seal.

Drive in radial seal (3) for output flange with special tool 23 2 300 .
Caution!
Use a plastic hammer to knock in.
Heat output flange to approx. 80°C (hot-air blower).

Push output flange onto output shaft.
If necessary, drive on to fit tight with special tool 23 1 160 .
Fit collar nut (1) with flat side pointing to output flange with screw retaining
compound, refer to BMW Parts Service.
Secure collar nut with drive socket 23 2 320.
Heat ball bearing inner race (2) for countershaft to approx. 80°C (hot-air
blower).
Press on ball bearing inner race (2) with special tool 23 1 160 until firmly
seated, drive on with gentle taps if necessary.
Install washer (3) and screw (4) with screw retaining compound, refer to
BMW Parts Service.Caution!
Screw (4) has left-hand thread.
Remove special tool 23 2 250 from gear train.

Engage a gear.
Tighten down screw (4).
Disengage selected gear again.
Install sealing cap (1) and drive in with special tool 23 2 150 until flush.
Coat half shell (2) with sealing compound, refer to BMW Parts Service, in
area of screw bore and install.
Install pin (3), thrust washer (4), needle bearing (5) and reverse gear
wheel (6) with collar (7) pointing to housing.
Coat collar of screw head with sealing compound, refer to BMW Parts
Service.
Install screw (8) with screw retaining compound, refer to BMW Parts
Service, but do not tighten down.
Install 5th/reverse gear shift arm with sliding blocks with catch (1) to left in
5th/reverse gear sliding sleeve.
Insert locking lever (1) with long tongue (2) into slot of 5th/reverse gear
shift arm.
Swivel locking lever (1) inwards and in so doing engage in recesses of
1st/2nd and 3rd/4th gear shift arms.
Center locking lever (1) by hand with bores.

Install bearing pins (2) and (3) on left and right and tighten down.
Carry out movement check on locking lever.
Insert selector shaft (4) in horizontal position.

Apply grease to 4 rollers.
Drive in radial seal (1) for selector shaft with special tool 23 2 260 .
Secure selector shaft with special tool 23 2 270 in neutral position.
Use a 8 mm bolt and cylindrical pin (2) from the shift joint or a suitable
mandrel for holding the shift shaft.
Clean front housing section.

Drive out sealing cap (3) for locking pin with a mandrel from inside to
outside.
Installation:
Replace sealing cap.
Replace bearing of drive shaft and retaining segments (1).

Remove retaining plates (1).
Insert magnets (4) in rear housing section.

Attach roller bearing (5) with small diameter facing outwards.
Note:
Coat needles with grease and press them in to avoid canting of the
needles when mounting the front case section.
Clean housing sealing surfaces and coat with sealing compound, refer to
BMW Parts Service.
Hold the 5th/reverse gear shift arm in horizontal position with a piece of
string to make installation easier.
Attach front housing section up to centering pin (1).

Insert 2 auxiliary screws M8 x 75 mm for centering housing opposing on
left and right in rear housing section.
Install special tool 23 2 293 in front housing section.
Attach special tool 23 2 290 to drive shaft.

Attach support shells (1) to drive shaft with conical side facing inwards.
Unscrewing the spindle presses the front case section on to the input
shaft.
Press on front housing section only to such an extent that auxiliary cord
can be removed again after installation of right bearing pin.
Center 5th/reverse gear shift arm (1) with bore and install right bearing
pin (2). Do not tighten down.
Note:
Replace bearing pin (2). Clean thread in housing.
Remove auxiliary cord.

Press on front housing section as far as it will go.
Remove special tool 23 2 290 completely.

Remove auxiliary screws from housing.
Clean front housing section to rear section.
Remove special tool 23 2 270 from selector shaft.
Center 5th/reverse gear shift arm (1) with bore and screw in left bearing
pin (2) by hand.
Screw in left bearing pin (2) by hand.
Tighten down bearing pins (2) on left and right.
Note:
Replace bearing pin (2). Clean thread in housing.
Install bearing pin (3) for locking lever.

This requires turning the transmission until bore (4) in the locking lever is
aligned with the bore in the case.
In this position, turn the bearing pins (3) by hand and secure.
Coat collar of screw head with sealing compound, refer to BMW Parts
Service.
Install screw (1) for reverse gear pin with screw retaining compound, refer
to BMW Parts Service.
Tighten both screws.
Install catch pins (1 ... 3) with pressure springs in shift arms.
Drive in sealing caps (5 ... 7) with special tool 23 2 360 .
Replace catch pin (8) and pressure spring (9).Caution!

Note installation position of catch pin (8) (roller horizontal).
Install sealing cap (1) with special tool 23 2 350 in bore bore (2).
Push sealing cap (1) inwards as far as possible.
Install retaining ring (3) and press in with special tool 23 2 350 up to
groove.
Check for correct seating of retaining ring (visual inspection).
Install reverse gear switch.
Install spacer (4).

Caution!
To prevent damage to drive shaft, attach special tool 23 2 380 to
drive shaft while installing retaining ring (3).
Slide retaining ring (3) over special tool 23 2 380 and install in groove.
Retaining ring must be seated without play in groove.
Replace retaining ring with a matching retaining ring. Retaining rings are
available in various thicknesses.
Sizes: 2.2 ... 2.6 mm
Coat sealing lip of radial seal with ATF.

Attach special tool 23 2 380 to drive shaft.
Push on radial seal (1) up to housing.
Drive in radial seal (1) with special tool 23 2 340 until flush.
Caution!
Use plastic hammer to drive in.
Install guide tube.

23 21 805 Replacing bearings on all transmission shafts (S5D 260Z / 310Z /
320Z)

00 5 500
23 1 220
23 1 260
23 1 280
23 1 300
23 1 440
23 1 470
23 2 310
33 4 020
Remove drive and output shafts.
Rear Case Section:

Release screws.
Remove retaining plates (1 and 2).
Lever out radial seal for output flange.Installation:

Replace radial seal.
Drive out ball bearing for output shaft with special tool 23 1 440 towards
inside.
Countershaft:
Heat housing in area of ball bearing to approx. 80°C (hot-air blower).
Withdraw ball bearing (1) towards inside.
Clean dirt from rear housing section.
Heat rear section of housing uniformly in area of ball bearing to approx.

80°C (hot-air blower).
Insert ball bearings for output shaft/countershaft.
Insert ball bearing (1) for countershaft with stepped side (1) towards
inside.
Drive in ball bearing until it is firmly seated:

Drive in output shaft with special tools 23 1 470 and 00 5 500 .
Drive in countershaft with special tools 23 1 220 and 00 5 500 .
Install retaining plates.
Install screws with screw retaining compound, refer to BMW Parts
Service, and tighten down.
For replacement of bearing inner race (2), 3rd/4th gear wheel must be
pressed off with special tool 23 2 310 .
For removal, refer to Replacing synchronizing mechanism, 3rd/4th gear.
Bearing in front housing section.

Drive shaft:
Release screws.
Remove retaining plates (1).

Withdraw ball bearing (2), if necessary drive out with special tool 23 1 440
from outside to inside.
Install ball bearing (2), if necessary drive in with special tool 23 1 470 until
firmly seated.
Install retaining plates (1).

Install screws with screw retaining compound, refer to BMW Parts
Service, and tighten down.
Countershaft:
Install special tool23 1 280 in bearing shell (1) for roller bearing.
Fit special tool 33 4 020 .

Screw on special tool 23 1 300 .
Withdraw bearing shell.
Installation:
Install bearing shell (1) in such a way that slot in bearing shell is flush
with knob (2) (turning lock) in housing.
Drive in bearing shell (1) with special tool 23 1 260 and special tool
00 5 500 .
23 21 008 Replacing output flange for transmission (GS5-39DZ)
Note:
This work step is identical to the work step ”Replacing radial seal for
output flange”.
23 21 005 Replacing output flange for transmission (S5D 310Z / S5D 320Z)
This operation is identical to the work step ”Replacing radial seal for
output flange”.
23 23 507 Disassembling and assembling all synchronizing mechanisms
(S5D 260Z / 310Z / 320Z)

23 1 160
23 1 290
23 2 250
23 2 310
33 1 342
Remove drive and output shafts.
Detach 1st/2nd and 3rd/4th gear shift arms.

Detach drive shaft (1), synchronizer ring (2) and roller bearing (3).
Grip gear train at output shaft (use protective vise jaws).
Detach 5th/reverse gear sliding sleeve.
Caution!
Loose thrust pieces, balls and springs.
Remove retaining ring (4) and spacer (5).

Installation:
Replace retaining ring (4).
Move 1st/2nd gear sliding sleeve in direction of 2nd gear.

Position press-off supports on 1st gear wheel.
Press following parts off output shaft:
Guide sleeve
Reverse gear wheel with synchronizer ring
Needle bearing
Bearing sleeve
1st gear wheel
Thrust washer
Pull off following parts:

Needle bearing
Synchronizer ring
Intermediate ring
Outer race
Detach 1st/2nd gear sliding sleeve.

Caution!
Loose thrust pieces, balls and springs.
Lever out retaining ring (1).

Remove spacer (2).
Installation:
Replace retaining ring (1).
Position press-off supports on 2nd gear wheel.
Press guide sleeve, 2nd gear wheel with synchronizing mechanism and
needle bearings off output shaft.
Assembling gear train:

Fit needle bearings and 2. gear wheel with recesses facing upwards.
Attach synchronizing mechanism.

Consisting of:
Place the inner race (1), intermediate ring (2) with drives (3) in the
recesses of the 1st gear wheel and synchronizer ring (4).
Check 2nd gear synchronizing mechanism for wear.

Measure distance X between gear wheel and synchronizer ring. In so
doing, press down uniformly on the synchronizer ring by hand.
Specification: at least 0.9 mm
Actual new part distance: 1.1 ... 1.6 mm.
When replacing, all three parts must be replaced at one time.
Heat guide sleeve to approx. 80°C (hot air blower).
Fit guide sleeve with long collar facing 2nd gear wheel.
When fitting, make sure driver lugs (5) of inner race are flush with
recesses (6) on gear wheel.
In addition, driver lugs (7) on synchronizer ring must engage in grooves
(8) of guide sleeve.
Press on guide sleeve with special tool 23 1 290 until firmly seated.
Install spacer (2).

Install retaining ring (1).
Retaining ring must be seated without play in groove; if necessary,
replace spacer (1).
Spacers are available in different thicknesses
Sizes from 1.8 ... 2.05 mm.
Insert 3 thrust pieces (1) and 3 pressure springs (2) in recess in guide
sleeve.
Fit 1st/2nd gear sliding sleeve with flat side facing upwards or with angled
side facing 2nd gear wheel.
The three set-back or opened teeth must point to the springs.
Tilt thrust pieces (1) individually as far out of sliding sleeve until balls (3)
can be placed on pressure springs.
Press balls (3) inwards. Simultaneously press thrust pieces into sliding
sleeve.
Pull sliding sleeve uniformly upwards up to lock (neutral setting).
Check 1st gear synchronizing mechanism for wear.

When replacing, all three parts must be replaced at one time.
Place synchronizer ring (1), intermediate ring (2) and inner race (3) with
driver lugs (4) in recesses (5) in guide sleeve.
Fit needle bearing.
Fit 1st gear wheel with grooves (6) facing driver lugs (7).
Heat thrust washer (9) and bearing bush (8) to approx. 80°C (hot air
blower) and attach to output shaft, press on if necessary.
Thrust washer with special tool 23 1 290 .
Bearing bush with special tool 33 1 342 .
Check reverse gear synchronizing mechanism for wear.

Fit needle bearing and reverse gear wheel.

Fit reverse gear synchronizer ring on reverse gear taper.
Heat 5th/reverse gear guide sleeve to approx. 80°C (hot air blower). Fit
output shaft with tapered end (1) facing upwards; if necessary, press on
with special tool 33 1 342 until firmly seated.
Make sure driver lugs (3) engage in recess (2).
Insert spacer (5) and retaining ring (4).

Retaining ring (4) must be seated without play in groove; if necessary,
replace spacer.
Spacers are available in different thicknesses
In sizes from 3.6 ... 4.0 mm.
Gently knock retaining ring inwards.
sleeve.
Fit sliding sleeve with stepped side (1) facing reverse gear wheel.
can be placed on pressure springs. Press balls (3) inwards.
Simultaneously press thrust pieces into sliding sleeve.
Insert 5th gear synchronizer ring in sliding sleeve. Pull sliding sleeve
uniformly upwards up to lock (neutral setting).
Check 5th gear synchronizing mechanism for wear.

Insert synchronizer ring.

Attach needle bearing and drive shaft to 5th gear wheel.
Countershaft:
Replace 3rd/4th gear synchronizing mechanism.
Fit special tool 23 2 310 on 3rd gear wheel.
Press bearing inner race (1), thrust washer, 4th gear wheel with needle
bearing, synchronizing mechanism and 3rd gear wheel with needle
bearing off countershaft.
Assembling:
Check 3rd/4th gear synchronizing mechanism for wear.
Fit needle bearings and 3th gear wheel.
Pull 3rd/4th sliding sleeve off guide sleeve.Caution!

Loose balls, springs and thrust pieces.
Fit synchronizer ring on 3rd gear taper.

Heat 3rd/4th gear guide sleeve to approx. 80°C (hot air blower).
Fit guide sleeve with long collar (1) facing 3rd gear wheel.
When fitting, make sure driver lugs (2) are flush with recesses on guide
sleeve.
If necessary, press the guide sleeve on to fit tight with help of special
tool 23 1 290 .
Heat bearing inner race (3) to approx. 80°C (hot air blower) and attach to
countershaft.
If necessary, press it on to fit tight with help of special tool 33 1 342 .
sleeve.
Fit 3rd/4th gear sliding sleeve with stepped side (3) facing upwards.
can be placed on pressure springs.
Press balls (3) inwards. Simultaneously press thrust pieces into sliding
sleeve.
Insert 4th gear synchronizer ring (4) in recesses in guide sleeve.

Pull sliding sleeve uniformly upwards up to lock (neutral setting).
Fit needle bearing and 4th gear wheel.

Caution!
The needle bearing has been selected by the manufacturer in
accordance with a specific tolerance and is green in color.
Do not mix up with other needle bearings.
Heat thrust washer (2) and bearing inner race (1) to approx. 80°C (hot air
blower) and attach to countershaft with collar (3) facing downwards.
If necessary, press them on to fit tight with help of special tool 23 1 160 .
611 Circlip 621 Gate plate

612 Cap 623 Bolt
613 Spring 624 Spring
614 Locking pin 625 Reversing lever
615 Spring 626 Retainer
616 Stop plate 627 Spring
617 Bolt 628 Catch pin
618 Roller 629 Roller
619 Selector arm 630 Shift shaft
620 Spring
601 5th/reverse gear shift arm 606 Shoulder shaft

602 Slide 607 3rd/4th gear shift arm
603 Bearing shaft 608 Cap
604 1st/2nd gear shift arm 609 Spring
605 Locking lever 610 Catch pin

00 1 450
23 0 170
23 4 021
23 4 022
23 4 023

00 1 450 .
Note:

Important!
Installation:
Note:
be mixed up.

Installation:
Note:

tool.Important!
go.Important!


Fit retaining ring.
23 30 ... Replacing catch pin (S5D ...Z and GS5-39DZ / C- and F-
transmissions)

00 1 450
23 0 170
23 0 490
23 2 360
23 3 110

Remove gearbox

00 1 450 .
Stamp a small hole into sealing cover (e.g. with scribing tool).
Screw special tool 23 0 490 into sealing cover.
Drive out sealing cover upwards.
Caution!
Do not damage edge of bore hole in transmission housing. A burr or
a dent may cause the sealing cover to leak.
Lift pressure spring and sleeve out of transmission housing with
magnet (1) or grippers.
Installation:
Following new components must be fitted in succession:
1. Collared bushing
2. Stop pin
3. Spring
4. Cap
Caution!
It must be possible to drive in the collared bushing without the
exertion of great effort.
Anodized layer of collared bushing must not be damaged.
Screw in collared bushing (1) partially with slot (S) counterclockwise (90°
to direction of travel).
Drive collared bushing with special tool 23 3 110 and plastic hammer into
transmission housing as far as it will go.
Insert stop pin (2) and pressure spring (3) in collared bushing.
Drive sealing cover (7) with special tool 23 2 360 into transmission
housing as far as it will go.Note:
Repeat task with the catch pins (5 and 6) of the other gears.

00 1 450
23 0 170
23 4 021
23 4 022
23 4 023

00 1 450 .
Note:

Important!
Installation:
Note:
be mixed up.

Installation:
Note:

tool.Important!
go.Important!


Fit retaining ring.
00 .. . Notes on SMG transmission service functions
Note:
The service functions must be carried out in the relevant order!
When replacing SMG control unit 1. Teach in clutch valve characteristic values
4. Teach in offset of longitudinal-acceleration sensor
Before working on the hydraulic 1. Reduce hydraulic pressure
system, if the system:
- is to be opened
- is filled with hydraulic fluid
(depressurization of hydraulic
system)
After working on the hydraulic 1. Bleed actuator block
system, if the system was opened
After removal and reinstallation of 1. Teach in clutch valve characteristic values
parts (no replacement of parts!)
- Engine
- Transmission
- Clutch
When replacing transmission Note: Perform points 1 and 2 only if the hydraulic system was
opened.
When replacing hydraulic unit with
actuator block 1. Bleed actuator block
When replacing engine 2. Bleed clutch slave cylinder and hydraulic lines
When replacing clutch Note: Perform point 1 only if the hydraulic system was opened.
When replacing individual clutch parts: 1. Teach in clutch valve characteristic values
- Release lever 2. Teach in clutch slipping point
- Ball pin 3. Reset clutch curve (automatically carried out by BMW diagnosis
- Release bearing ...
When replacing clutch slave cylinder 1. Bleed actuator block
with PLCD sensor
When replacing longitudinal- 1. Teach in offset of longitudinal-acceleration sensor
acceleration sensor

A Transmission type
S = Manual gearbox

S Type of top gear
D = Direct gear
S = Overdrive gear

G = Getrag
J = Jatco

G Transmission
S Transmission type
S = Manual gearbox

-
26 = D-transmission
31 = C-transmission
39 = F-transmission
37 = H-transmission
53 = G-transmission
17 = I-transmission
45 = K transmission
B Gear set
S= Sport gear ratio
G = Getrag
A = AISIN
Manual gearbox:





GS6-58DG/BG Getrag
GS6-59DG/BG Getrag

A5S 310Z ZF 5HP-18

A5S 325Z ZF 5HP-19
A5S 440Z ZF 5HP-24
A5S 560Z ZF 5HP-30
A5S 360R / 390R GM GM5

GA6HP19Z ZF 6HP19
GA6HP26Z ZF 6HP26
GA6HP32Z ZF 6HP32
GA6L45R GM GM6

GA8G45 AISIN 8G45
GA8HP45Z ZF 8HP45
GA8HP50Z ZF 8HP50
GA8HP51Z ZF 8HP51
GA8HP70Z ZF 8HP70
GA8HP75Z ZF 8HP75
GA8HP76Z ZF 8HP76
GA8HP90Z ZF 8HP90
GA8HP95Z ZF 8HP95

00 2 030
23 4 050
Note:
Important!
screws (2).
means of screw.
Important!

0 495 187
24 0 200
Note:
Attention!
transmission.
(Danger of injury)
transmission.
Attention!
24 00 018 Adjusting selector lever (A5S 360R / 390R, A4S 200R, 6HP26Z/19Z)
Note:
Check cable for ease of movement.
Move selector lever to ”P” position.
Grip clamping sleeve (1).

Slacken nut (2).
Press selector lever (3) forwards into park position. Press cable (4) in
direction of arrow and release again.
Tighten down nut (2).
Installation:
Move selector lever to ”P” position.
Check whether parking gear is engaged by turning propeller shaft.
00 11 500 Checking/topping up fluid level in automatic transmission (A5S
360R / 390R, A4S 200R / 310R)
Important!
transmission.

Details of approved fluid type,
refer also to adhesive label on transmission fluid sump.
Move selector lever to parking position ”P”.

The vehicle must be horizontal and secured against rolling off.
Note:
Picture shows transmission for vehicles with gasoline engines. The
filler plug is located at the front on vehicles with diesel engines and
on transmissions A4S 200R (GM4).
Connect BMW Diagnosis and Information System (DIS) or BMW MoDiC

to vehicle.
Screw in oil filler plug (1) by hand.
Start engine and run at idle speed.
Operate brake and, with engine at idle speed, change up and down all
gears several times.
Release oil filler plug (1) again.
Increase temperature of automatic transmission fluid to 30 ... 50 °C.
Interrogate temperature of automatic transmission fluid with MoDiC or
DIS.
Run engine at idle speed.
Screw in oil filler plug (1).
Installation:
Check sealing ring on filler plug (1) for damage and if necessary
replace sealing ring and filler plug.
Headaches
Dizziness
Stomach aches
Vomiting
Diarrhoea
Cramps/fits
Unconsciousness

or mugs)
First aid measures:

immediately.
Note:

Tightening torque,


Note:
Start engine.

20 3 . . . 15
25 5 . . . 17
30 8 . . . 20
35 11 . . . 22
40 13 . . . 25
45 14 . . . 26
50 16 . . . 27
55 17 . . . 28
60 19 . . . 29
65 21 . . . 32
70 22 . . . 34
75 24 . . . 36
80 26 . . . 38
85 29 . . . 41
90 31 . . . 43

Installation:
Tightening torque,

Start engine.
24 00 028 Removing and installing automatic transmission (A5S 360R / 390R,
M47/ M57)

00 2 030
11 8 022
24 1 110
24 2 300
24 4 131
24 4 135
24 5 301
24 5 305
Note:
After completion of work, check transmission fluid level.
Caution!
Use only the approved automatic transmission fluid in this automatic
transmission.

Disconnect battery.
Engine M57
Detach gaiter (1) from intake hood (2).
M47 engine:
Caution!
The section "Removing and installing reinforcement plate" contains
Note:
Reinforcement plate is fitted in:
- Coupés from 11/99
- All convertibles
- All E46 models without 4WD from 12/2000


Release nut (2).
Installation:
Adjust selector lever.
Grip cable (1) at hexagon (2).

Release nut (3).
Pull cable (1) out of holder.
Support transmission with special tools 00 2 030 / 24 5 301 / 24 5 305 .
Release screws.
Tightening torque, 24 71 1AZ/2AZ.
Remove cross-member (1).
Release screws.
Installation:
Grip propeller shaft.

Release nuts.
Note on installation M57:

Pull off cover tape from butylene tape on both sides.
Stick butylene tape (1) to outside of center bearing (2).
Butylene tape,
Caution!
Remove butylene tape already attached to center bearing.
Clean adhesive area on center bearing and on body.
Then coat adhesive area on body with mineral oil.
This coating with oil is necessary to facilitate insertion of the sticky
butylene tape in the propeller shaft tunnel.
This prevents the butylene tape from being deformed.
Note on installation M57:
Press center bearing (2) into transmission tunnel.

Caution!
Position special tool 11 8 022 in such a way that engine oil sump
rests safely on special tool.
Tighten down knurled screws until special tool 11 8 022 rests against
engine oil sump.
Unlock cable plug (1) and disconnect.

Unclip cable from transmission housing.
Release screw (1).

Withdraw hydraulic lines (2) to oil cooler from transmission housing.
Installation:
Replace sealing rings.
Remove cover.
Release retaining screws of torque converter (3 x) with special tool

24 1 110 .
Installation:
Use only original screws.
Protect torque converter from slipping out. To do so, insert special tool
24 4 131 / 24 4 135 in opening in transmission housing.
Clamp torque converter.
Release screws.
Pull off transmission from engine towards rear and lower it.
Installation:
Pay attention to adapter sleeves (1 and 2).
Withdraw damaged adapter sleeves from transmission housing. Insert

new adapter sleeves into engine block.
Installation:
The sheet metal flywheel is equipped with three recesses for the
torque converter retaining lugs.
When joining together engine and transmission, the three retaining
lugs on the torque converter must be aligned with the three
recesses in the sheet metal flywheel.
Failure to comply with this requirement leads to secondary damage
on the automatic transmission.
The torque converter or engine is not able to spin and would cause
damage.
Installation:
Bore on driver must point to center of aperture in cover plate.
Installation:
Turn torque converter on transmission until bores on lugs point to
center of bore on flywheel.
Screw special tool 24 2 300 into lug.
Installation:
Raise automatic transmission until bore on driver is reached.
Carefully insert transmission into bore on driver with special tool
24 2 300 .
Flange transmission housing to engine.
Remove special tool 24 2 300 from lug towards front.
24 00 028 Removing and installing automatic transmission (A5S 390R,
M47TU)

00 2 030
11 8 022
24 1 110
24 2 300
24 4 131
24 4 133
24 5 301
24 5 305
Important!
transmission.


Disconnect battery.
Remove front assembly underbody protection.


Loosen nut (2).
Installation:
Adjust selector lever
Grip cable (1) at hexagon head (2).

Unscrew nut (3).
Pull cable (1) out of holder.
Unclip cable from transmission housing.
Unscrew bolt (1).

Pull hydraulic lines (2) to transmission fluid cooler out of transmission
housing.
Installation:
Unfasten screws.
Unclip cable from cross-member.
Remove cross-member (1)
Unfasten screws.
Installation:

Unscrew nuts.

Important!
Position special tool 11 8 022 in such a way that engine oil sump
rests safely on special tool.
Tighten down knurled screws until special tool 11 8 022 rests on engine
oil sump.
Lift off cover.

Release retaining screws on torque converter (3 screws) with special
tool 24 1 110 .
Installation:
Only use original bolts.
Protect torque converter from slipping out. To do so, insert special tool
24 4 131 / 24 4 133 in opening of the transmission housing.
Clamp torque converter.
Unfasten screws.
Installation:
Pay attention to installation position of exhaust mounting.
Pull off transmission from engine towards rear and lower it.
Installation:
Pay attention to adapter sleeves (1 and 2).
Withdraw damaged adapter sleeves from transmission housing. Insert

new adapter sleeves into engine block.
Installation:
Sheet metal flywheel is provided with three recesses for retaining
lugs of torque converter.
When joining up engine and transmission: The three retaining lugs
on the torque converter must be flush with the three recesses on
the metal flywheel.
Non-conformance leads to follow-up damage on the automatic
transmission.
Turning on the torque converter, or engine, is no longer possible
after guiding the engine and transmission together and would lead
to damage.
Installation:
Bore on driver must point to center of aperture in cover plate.
Installation:
Rotate torque converter on transmission.
Bores on lugs must point to center of bores on flywheel.
Screw special tool 24 2 300 into lug.
Installation:
Raise automatic transmission until bore on driver is reached.
Carefully insert transmission into bore on driver with special tool
24 2 300 .
Flange transmission housing to engine.
Remove special tool 24 2 300 from lug towards front.
24 00 045 Removing and installing replacement transmission (A5S 360R /
390R, A4S 200R)
Drain off automatic transmission fluid.
Recycling:
Caution!
Before installing replacement transmission: Always flush oil cooler
with lines.
Remove and install transmission.Note:

Automatic transmission is supplied filled with transmission fluid.
Note:
Caution!
transmission.
Convert transportation lock (1).

Caution!
After removing transportation lock: Protect torque converter from
slipping out.
Transmission identification,
refer to Parts Service, on rating plate.
Convert lever (2) and retaining bracket (3).
Convert exhaust suspension.
Convert all cable holders.
Remove transfer case.
24 00 ... Removing and installing sealing cap on working piston (A4S 310R)

24 1 351
24 1 352
24 1 353
Note:
Caution!
transmission.
Failure to comply with this requirement will result in serious damage
to the automatic transmission!
Recycling:
Catch and dispose of emerging transmission fluid.

Remove heat shield.
Release center bearing on propeller shaft.
Carefully lower transmission at rear slightly.
Note:
The procedure and tightening torques are described in the section
”Removing and installing transmission”.
Clean surface of snap ring.

Prepare special tool 24 1 351 :
Unscrew screw (1).
Press up clamping bar (2) on screw (1).
Screw in special tool 24 1 351 partially.

Caution!
Adapt special tool to transmission.

Tension special tool at handles (2) (piston is pressed in slightly, strain is
removed from snap ring).
Remove special tool.
Remove snap ring (1).
Screw in special tool 24 1 352 until it is firmly connected to sealing

cap (1).
Remove sealing cap by screwing special tool 24 1 353 onto special tool
24 1 352 .
Rub edge of new sealing cap with transmission fluid and install sealing
cap (1) with special tool 24 1 351 .
Press in sealing cap (1) on screw (2) of special tool 24 1 351 until groove
for snap ring (3) is exposed.
Remove special tool.
Insert snap ring in groove (3).
Caution!
Make sure snap ring is correctly seated in groove.
Danger of injury!
Impaired sight

First aid measures:

Warning!
Recycling:

ground.

A Transmission type
S = Manual gearbox

S Type of top gear
D = Direct gear
S = Overdrive gear

G = Getrag
J = Jatco

G Transmission
S Transmission type
S = Manual gearbox

-
26 = D-transmission
31 = C-transmission
39 = F-transmission
37 = H-transmission
53 = G-transmission
17 = I-transmission
45 = K transmission
B Gear set
S= Sport gear ratio
G = Getrag
A = AISIN
Manual gearbox:





GS6-58DG/BG Getrag
GS6-59DG/BG Getrag

A5S 310Z ZF 5HP-18

A5S 325Z ZF 5HP-19
A5S 440Z ZF 5HP-24
A5S 560Z ZF 5HP-30
A5S 360R / 390R GM GM5

GA6HP19Z ZF 6HP19
GA6HP26Z ZF 6HP26
GA6HP32Z ZF 6HP32
GA6L45R GM GM6

GA8G45 AISIN 8G45
GA8HP45Z ZF 8HP45
GA8HP50Z ZF 8HP50
GA8HP51Z ZF 8HP51
GA8HP70Z ZF 8HP70
GA8HP75Z ZF 8HP75
GA8HP76Z ZF 8HP76
GA8HP90Z ZF 8HP90
GA8HP95Z ZF 8HP95

00 2 030
23 4 050
Note:
Important!
screws (2).
means of screw.
Important!

0 495 187
24 0 200
Note:
Attention!
transmission.
(Danger of injury)
transmission.
Attention!
24 30 009 Removing and installing/replacing selector unit (A5S 360R/390R,
A4S 200R)
Important!
transmission.


Remove and install transmission fluid sump.
Remove and install/replace transmission fluid screen.
Disconnect all plug connections on shift unit.

Unclip temperature sensor (1) from holder.
Note:
As of model year 2001 (04/2000), the temperature sensor is integrated in
the wiring harness.
Important!
Do not release screws (1).
Release all other screws, with outside torx E8, on shift unit and remove
shift unit.
A5S 360R (GM5) transmission:

Pull out seals (1), (2) and (3).
Coat new seals with automatic transmission fluid and install.
Pull out seals (2) and (3).
Caution!
A4S 360R (GM4) transmission without seal (1).
Installation:
Blow out tapped holes with compressed air gun.
Insert both supplied set screws (1) into tapped holes.
Length of screws:
(1) = (2) = 68 mm, all others = 50 mm.
Install shift unit with aid of both set screws and secure in place with
screws.
Remove both set screws. Tighten all screws until it is hand-tight.
When tightening screws:
follow sequence without fail.
Do not tighten screws (1) and (2) yet.
Suspend guide (1) of transmission switch in detent spring (2).Important!

Journal (3) of detent disk must be located in groove (4) of slide
valve.
Insert feeler gauge (1) between detent spring (2) and detent disk (3) and
set gap of 0.80 mm by moving detent spring (2).
24 11 100 Removing and installing/replacing transmission screen (A5S 360R
/ 390R, A4S 200R)
Important!
Use only the approved automatic transmission fluid.


Remove transmission oil sump.
Pull off transmission fluid screen (1) towards bottom and remove.
If the sealing ring (1) has remained in the pump housing, it must be
removed and the transmission fluid screen replaced.
Installation:
Different transmission fluid screens are used in petrol/gasoline and
diesel engines.
Therefore check specified measurement A prior to installation.
Measurement A:
Gasoline engine:
- M52TU = 39.00 ± 1.00 mm
- M43TU = 30.00 ± 1.00 mm
Diesel engine:
- M57 = 30.00 ± 1.00 mm
Position (1): Two gaskets are fitted.
24 11 001 Removing and installing/sealing or replacing transmission fluid
sump (A5S 360R / 390R, A4S 200R)
Note:
Caution!
transmission.

M47 / M47TU:
Open drain plug (1).

Drain off automatic transmission fluid.
Unscrew all bolts.
Remove oil sump (2).
Detach gasket from oil sump (2).
Installation:
Replace sealing ring on drain plug.
Fit new gasket on oil sump.

Clean magnets (1) and reinstall in oil sump.
Install oil sump.
Insert all screws until contact is made with screw head in each case.
Caution!
Tighten down screws, not in diagonal sequence but rather in order,
1x to specified torque.
24 12 009 Replacing radial shaft seal for torque converter (A5S 360R / 390R,
A4S 200R)

00 1 450
00 2 550
00 5 010
24 0 180
24 4 000

Remove automatic transmission.
Important!
transmission.

Secure transmission with special tool 24 0 180 to assembly stand

00 1 450 .
Screw special tool 24 4 000 into torque converter.

Remove torque converter and set down vertically.
Release retaining screws (1) of radial shaft seal.
Pull radial shaft seal (1) out of converter housing with special tool
00 5 010 .
Installation:
Coat sealing lips of radial shaft seal with automatic transmission
fluid.
Insert radial shaft seal.
Tighten both retaining screws uniformly.
Push torque converter through radial shaft seal onto transmission shaft
as far as it will go.
Press torque converter by hand into converter housing. Turn in so doing
until opening of converter hub engages in driver of pump impeller. Torque
converter must noticeably slide inwards.
Determine distance between contact surface and surface (1) of tapped
hole in torque converter with special tool 00 2 550 .
Torque converter is correctly installed when measured value is greater
than 30 mm.
24 21 . . . Installing output flange add-on kit (A5S 360R)

31 2 220
Note:
Caution!
transmission.

Place transmission in selector lever position "P".
Caution!
Risk of injury: only carry out work on the exhaust system after it has
cooled down.
Installation:
Coat threads with -CRC- copper paste, refer to BMW Parts Service.
Check gaskets (1), replace if necessary.
Support exhaust system with jack and special tool 31 2 220 and secure
against falling out.
Release screws (1/2) and remove reinforcement plate (3). Front

reinforcement plate is connected to exhaust system via rubber mounts.
Release screw (1) and remove exhaust suspension.Installation:

After complete installation of exhaust system, align exhaust
suspension so that it is free from tension. To do so, slacken screws
(2).
Front rubber mount on rear muffler: Release hexagon nuts (1).
Rear rubber mount on rear muffler: Release hexagon nuts (1).

Release screws.
Installation:
Grip propeller shaft and release nuts.
Bend propeller shaft downwards at center mount (1). Detach propeller
shaft from transmission output flange and tie back to side on vehicle
underbody.
Grip output flange (1) with special tool 23 0 020.

Release hexagon nut.
Detach output flange (1).
Installation:
Install hexagon nut with screw retaining compound.
Prepare add-on kit:

1) Snap ring
2) Sealing ring
3) Output flange
4) Spring washer
5) Flat nut
Coat sealing ring (1) with gear oil and insert in groove of output flange
(2).
Push snap ring (1) onto spline shaft (2), ensuring that shaft seal is not
damaged.
Push output flange (2) onto output shaft and install spring washer (1).
Note installation direction of spring washer (1).
Fit hexagon nut (1) on output flange (2).

Installation:
24 13 002 Removing and installing or replacing transmission extension
housing (A5S 360R / 390R)

00 2 030
00 2 550
00 5 010
23 0 020
24 1 090
24 5 301
24 5 305
Note:
After completing work, top up transmission fluid level.
Caution!
transmission.

Caution!
In E39 vehicles with M57 engines, remove complete automatic
transmission.
The automatic transmissions in question each have an adhesive
label on the extension housing at the rear (see fig.).
To avoid damage to the transmission: position the transmission on
the assembly stand for the entire operation (output flange facing
upwards).
Remove and install automatic transmission.
Release screws.
Release screws.
Installation:

Bend propeller shaft downwards at center bearing (1). Detach propeller
underbody.
Caution!
In E39 vehicles with M57 engines, remove complete automatic
transmission.
To avoid damage to the automatic transmission: position the
transmission on the assembly stand for the entire operation (output
flange facing upwards).
Note:
The automatic transmissions in question each have an adhesive
label on the extension housing at the rear (see fig.).
Version 1 without spring washer:
Grip output flange (1) with special tool 23 0 020 .
Installation:
Replace sealing ring in output flange (1).
Version 2 with spring washer:

Release hexagon nut (1) on output flange (2).
Installation:

Remove spring washer (1).
Installation:
Remove output flange (2).

Installation:
Replace sealing ring in output flange (2).
Withdraw radial seal (1) with special tool 00 5 010 .

Release screws on transmission extension housing (1).
Carefully pull off transmission extension housing (1).
Replace gasket between transmission housing (1) and end

cover.Caution!
Existing shim (2) remains fitted and is not recalculated.
Caution!
If shim is lost:
Calculate new shim.
Calculate measurement between contact face (1) and parking gear (2)
with special tool 00 2 550 .
Calculate the new shim with this measurement from the following table.
Calculated measurement in mm Shim

15,99 - 16,27 0.95/1.05
16,27 - 16,47 1.15/1.25
16,47 - 16,67 1.35/1.45
16,67 - 16,87 1.55/1.65
16,87 - 17,07 1.75/1.85
17,07 - 17,27 1.95/2.05
17,27 - 17,47 2.15/2.25
17,47 - 17,67 2.35/2.45
17,67 - 17,87 2.55/2.65
17,87 - 18,07 2.75/2.85
Installation:
Coat sealing lips of new radial seal with automatic transmission fluid.
Drive in radial seal with special tool 24 1 090 until flush.

24 13 011 Replacing radial seal for output flange (A5S 360R / 390R)

00 2 030
00 5 010
23 0 020
24 1 090
24 5 301
24 5 305
Note:
Caution!
transmission.


Release screws.
Release screws.
Installation:
underbody.
Version 1 without spring washer:

Installation:
Replace inner sealing ring on output flange (1).

Release hexagon nut (1) on output flange (2).
Installation:

Remove spring washer (1).
Installation:
Withdraw radial seal (1) with special tool 00 5 010 .
Installation:
Coat sealing lips of new radial seal with automatic transmission fluid.
Drive in radial seal with special tool 24 1 090 until flush.
24 21 . . . Installing output flange add-on kit (A5S 360R)

31 2 220
Note:
Caution!
transmission.

Place transmission in selector lever position "P".
Caution!
Risk of injury: only carry out work on the exhaust system after it has
cooled down.
Installation:
Coat threads with -CRC- copper paste, refer to BMW Parts Service.
Check gaskets (1), replace if necessary.
Support exhaust system with jack and special tool 31 2 220 and secure
against falling out.
Release screws (1/2) and remove reinforcement plate (3). Front

reinforcement plate is connected to exhaust system via rubber mounts.
Release screw (1) and remove exhaust suspension.Installation:

After complete installation of exhaust system, align exhaust
suspension so that it is free from tension. To do so, slacken screws
(2).
Front rubber mount on rear muffler: Release hexagon nuts (1).
Rear rubber mount on rear muffler: Release hexagon nuts (1).

Release screws.
Installation:
Bend propeller shaft downwards at center mount (1). Detach propeller
underbody.
Grip output flange (1) with special tool 23 0 020.

Installation:
Prepare add-on kit:

1) Snap ring
2) Sealing ring
3) Output flange
4) Spring washer
5) Flat nut
Coat sealing ring (1) with gear oil and insert in groove of output flange
(2).
Push snap ring (1) onto spline shaft (2), ensuring that shaft seal is not
damaged.
Push output flange (2) onto output shaft and install spring washer (1).
Fit hexagon nut (1) on output flange (2).

Installation:
24 21 100 Replacing output flange (A5S 360R / 390R)

23 0 020
Note:
Caution!
transmission.

Release screws.
Installation:
Release nuts.
underbody.

Installation:
Installation:
Replace inner sealing ring (1) on output flange (2).
Caution!
There are two different output flanges; do not mix them up!
Version 1 (without spring washer)

Identifying features:
There is no spring washer fitted between the flange nut and output flange
to secure the output flange (2) on the flange nut (1).
When this output flange is replaced, the add-on kit detailed below must
be retrofitted.
Caution!
Only the modified version (Version 2) is still available as a
replacement.
Retrofit kit:
1 Snap ring
2 Sealing ring
3 Output flange
4 Spring washer
5 Flange nut
Install add-on kit for output flange,
refer to 24 21... Installing add-on kit for output flange.
Version 2 (with spring washer)

1 As the substitute, the output flange with spring washer (2) is
identified with a white marking (1) around its circumference.
Note:
In series production, the output flange with spring washer is fitted
from transmission serial number 7912 and has no color marking.
2 The spring washer (1) is fitted between flange nut and output flange
(2).
Caution!
If the version 2 output flange is replaced by a version 2 model, the
snap ring supplied in the add-on kit (see also Fig. R24 0489, item 1)
must not be replaced because the fitted snap ring is difficult to
remove. The fitted snap ring must be left in the transmission!
24 30 009 Removing and installing/replacing selector unit (A5S 360R/390R,
A4S 200R)
Important!
transmission.


Remove and install transmission fluid sump.
Remove and install/replace transmission fluid screen.

Note:
the wiring harness.
Important!
Do not release screws (1).
Release all other screws, with outside torx E8, on shift unit and remove
shift unit.

Pull out seals (1), (2) and (3).
Pull out seals (2) and (3).
Caution!
A4S 360R (GM4) transmission without seal (1).
Installation:
Blow out tapped holes with compressed air gun.
Insert both supplied set screws (1) into tapped holes.
Length of screws:
(1) = (2) = 68 mm, all others = 50 mm.
Install shift unit with aid of both set screws and secure in place with
screws.
Remove both set screws. Tighten all screws until it is hand-tight.
When tightening screws:
follow sequence without fail.
Do not tighten screws (1) and (2) yet.
Suspend guide (1) of transmission switch in detent spring (2).Important!

Journal (3) of detent disk must be located in groove (4) of slide
valve.
Insert feeler gauge (1) between detent spring (2) and detent disk (3) and
set gap of 0.80 mm by moving detent spring (2).
24 32 550 Replacing pressure regulator for converter lockup clutch (AS5
360R/390R, A4S 200R)
Important!
transmission.


Loosen shift unit by untwisting (approx. 4 turns) all 8 outside
torx screws and 1 hexagon screw.
Remove retaining spring.

Pull out pressure regulator (1) for converter lockup clutch.
Installation:
Coat new pressure regulator (1) for converter lockup clutch with
automatic transmission fluid.
24 32 560 Replacing pressure regulator for main pressure (A5S 360R/390R,
A4S 200R)
Important!
transmission.


Remove transmission sump.
Remove transmission fluid screen.
Disconnect plug (1) from pressure regulator (2) for main pressure.
Remove retaining spring (3).
Remove pressure regulator (2) for main pressure.
Installation:
Coat new pressure regulator (2) for main pressure with automatic
transmission fluid.
24 61 503 Programming/replacing control unit
Turn off ignition.

Connect MoDiC or DIS Tester.
Turn on ignition.
Select ”Programming”.
For subsequent procedure, follow MoDiC or DIS instructions.
Note:
Read the section on programming in the ”Diagnosis and Coding” service
information bulletin.
Installation location of control unit, refer to DIS Tester.
24 32 550 Replacing pressure regulator for converter lockup clutch (AS5
360R/390R, A4S 200R)
Important!
transmission.


Loosen shift unit by untwisting (approx. 4 turns) all 8 outside
torx screws and 1 hexagon screw.
Remove retaining spring.

Pull out pressure regulator (1) for converter lockup clutch.
Installation:
Coat new pressure regulator (1) for converter lockup clutch with
automatic transmission fluid.
24 32 560 Replacing pressure regulator for main pressure (A5S 360R/390R,
A4S 200R)
Important!
transmission.


Remove transmission sump.
Remove transmission fluid screen.
Disconnect plug (1) from pressure regulator (2) for main pressure.
Remove retaining spring (3).
Remove pressure regulator (2) for main pressure.
Installation:
Coat new pressure regulator (2) for main pressure with automatic
transmission fluid.
24 33 510 Replacing solenoid valve 1, 2 or 3 (A5S 360R / 390R, A4S 200R)
Important!
transmission.


Disconnect plug from solenoid valve.

Remove retaining spring and withdraw solenoid valve (1, 2 or 3).
Installation:
Coat new solenoid valve with automatic transmission fluid.
Caution!
Note position of wiring harness.
Note:
Allocation of solenoid valves (SV):
1 SV switching 1-2
2 SV switching 2-3
3 SV switching 4-5
Turn off ignition.

Turn on ignition.
Note:
24 35 551 Replacing pulse generator (output speed) (A5S 360R / 390R, A4S
200R)
Important!
transmission.


Pull off plug (1).

Unscrew bolt (2).
Withdraw pulse generator (3).
Read out fault memory of EGS control unit. Check stored fault
messages, eliminate faults and then clear fault memory.
24 35 550 Replacing pulse generator (turbine speed) (A5S 360R / 390R, A4S
200R)
Important!
Use only the approved transmission fluid.


Pull off plug (1).

Release screw (2).
Withdraw pulse generator (3).
Read out fault memory of EGS control unit. Check stored fault
messages, eliminate faults and then clear fault memory.
24 35 600 Replacing transmission switch (A5S 360R / 390R, A4S 200R)
Important!
transmission.


Move selector lever to position ”D”.
Remove and install selector unit.

Slacken nut (2).
Release nut (4).

Remove selector lever (3).
Installation:
Adjust selector lever
Note:
E46/16 (4WD)
Observe installation position of axial lock (spacer bushing) on manual
shift valve shaft between transmission switch and housing.
Removal of manual shift valve shaft is opposite to that shown in Fig.
R24 0433.
Drive spring pin (1) out of transmission switch (2).
Withdraw manual shift valve shaft (3) from transmission only so far that
transmission switch (2) can be removed.
Important!
Do not remove parking gear rack.
Do not move parking gear rack more than 10 mm; if necessary,
secure with pointed pliers.
Release notched disk on parking gear rack.

Remove transmission switch (2) with detent disk.
Remove transmission switch (1) from detent disk (2).Installation:

Bore holes for spring pin in transmission switch (1) must overlap
with bore holes of detent disk (2) and manual shift valve shaft.
Installation:
Attach parking gear rack (1) from rear in detent disk (2).
Slide in manual shift valve shaft.
Drive in spring pin.
Important!
During entire installation work, journal (3) must be aligned vertically
to manual shift valve shaft.
After installation of detent spring, ensure that parking lock functions
correctly.
Press journal (3) forwards into ”P” position, rotate propeller shaft and
check that locking pawl engages.
24 36 501 Replacing wiring harness in automatic transmission (A5S
360R/390R, A4S 200R)
Important!
transmission.


Remove transmission plug at rear right.
Note:
Pay attention to spacer on transmission fluid screen (1) on vehicles
with diesel engines.
Pull off transmission fluid screen (1) towards bottom and remove.
Note:
If the sealing ring (1) has remained in the pump housing, it must be
removed and the transmission fluid screen replaced.

Note:
the wiring harness.
Remove retaining clip with screwdriver (2). Insert transmission plug (1) in
transmission.
Remove wiring harness from automatic transmission.
Installation:
To facilitate installation, coat sealing rings with petroleum jelly.
Make sure transmission plug is in correct position.
24 40 009 Removing and installing/replacing torque converter (A5S 360R /
390R, A4S 200R)

00 2 550
24 4 000
Important!
transmission.


Remove automatic transmission.
Screw special tool 24 4 000 into torque converter.

Remove torque converter.
Note:
When torque converter is removed, transmission oil flows out.
Installation:
During installation: do not damage radial shaft seal and bearing.
If the torque converter is not correctly installed, the driver of the pump
impeller may be damaged when the transmission is flanged to the
engine.
Remove torque converter and set down vertically.

Push torque converter through radial shaft seal onto transmission shaft
as far as it will go.
Press torque converter by hand into converter housing and rotate in so
doing. Converter hub opening must snap into place in driver of pump
impeller. Torque converter must be felt to slip inwards.
Calculate measurement between contact face and area (1) of tapped
hole of torque converter with special tool 00 2 550 .
Torque converter is correctly installed when measured value is greater
than 30 mm.
24 50 001 Replacing radial shaft seal for manual shift valve shaft (A5S 360R /
390R, A4S 200R)

24 5 361
24 5 362
24 5 363
24 5 364
Important!
transmission.


Loosen nut (2).
Unscrew nut (1).

Screw special tool 24 5 361 into radial shaft seal.
Screw special tool 24 5 362 onto special tool 24 5 361 and tighten down.
This pulls the radial shaft seal out of the transmission housing.
Screw adapter sleeve (1) from seal set onto manual shift valve shaft.
Moisten sealing lips of radial shaft seal (2) with automatic transmission
fluid.
Push radial shaft seal (2) onto manual shift valve shaft. Press radial shaft
seal (2) as far as possible into transmission housing.
Grip radial shaft seal (2) firmly.
Unscrew adapter sleeve (1) from manual shift valve shaft.
Pull radial shaft seal into transmission housing up to stop with special
tools 24 5 363 and 24 5 364 .Installation:
E46 4WD:
Selector shaft sealing cap on left transmission side leaking.
Lever out sealing cap (1) with a screwdriver (2).
Place new sealing cap (1) on drift (2).Note:

Drift (2) for driving in sealing cap is contained in repair kit.
Drive in new sealing cap (1) with drift (2) as far as it will go.
24 50 001 Replacing radial shaft seal for manual shift valve shaft (A5S 360R /
390R, A4S 200R)

24 5 361
24 5 362
24 5 363
24 5 364
Important!
transmission.


Loosen nut (2).
Unscrew nut (1).

Screw special tool 24 5 361 into radial shaft seal.
Screw special tool 24 5 362 onto special tool 24 5 361 and tighten down.
This pulls the radial shaft seal out of the transmission housing.
Screw adapter sleeve (1) from seal set onto manual shift valve shaft.
Moisten sealing lips of radial shaft seal (2) with automatic transmission
fluid.
Push radial shaft seal (2) onto manual shift valve shaft. Press radial shaft
seal (2) as far as possible into transmission housing.
Grip radial shaft seal (2) firmly.
Unscrew adapter sleeve (1) from manual shift valve shaft.
Pull radial shaft seal into transmission housing up to stop with special
tools 24 5 363 and 24 5 364 .Installation:
E46 4WD:
Selector shaft sealing cap on left transmission side leaking.
Lever out sealing cap (1) with a screwdriver (2).
Place new sealing cap (1) on drift (2).Note:

Drift (2) for driving in sealing cap is contained in repair kit.
Drive in new sealing cap (1) with drift (2) as far as it will go.
Replacement:
Programming
Coding
Turn off ignition.

Turn on ignition.
Note:
Note:

Tightening torque,


Note:
Start engine.

20 3 . . . 15
25 5 . . . 17
30 8 . . . 20
35 11 . . . 22
40 13 . . . 25
45 14 . . . 26
50 16 . . . 27
55 17 . . . 28
60 19 . . . 29
65 21 . . . 32
70 22 . . . 34
75 24 . . . 36
80 26 . . . 38
85 29 . . . 41
90 31 . . . 43

Installation:
Tightening torque,

Start engine.
25 11 000 Removing and installing shift lever

25 1 120

GS6-37BZ/DZ and 53BZ/DZ transmissions only:
Remove exhaust system (M54/ M57/ M57TU).
Remove heat shield (M54/ M57/ M57TU).
Remove transmission cross-member (M47TU).
Note:
Do not twist knob during removal as this would cause the turning
lock in the knob to shear off.
Tug firmly to remove knob.Installation:

Fit knob on shift lever, align and press on until it snaps noticeably
into place.
Installation:
Slide gaiter (1) downwards until groove (2) is completely exposed.
Installation:
Feed gaiter (1) downwards and fit on shift lever (2).
Pull rubber gaiter (1) over selector lever and insert in centre
console.
Press installation frame of rubber gaiter (1) together a little and remove
rubber gaiter (1) from centre console.
Remove soundproofing (1).
Lift off retainer (1).

Remove disk (2).
Remove selector rod (3).
Installation:
Grease shift rod pin.
Important!
New retaining clips fitted as from 04.08.
Retaining clip must interlock captively with retaining web (1) behind
shift rod pin.
Insert special tool 25 1 120 in mounting and turn 90° counterclockwise.
Press mount upwards out of shift arm.
Remove rubber gaiter from body cutout and lift out with selector lever.
Installation:
Pull inner rubber gaiter over bowl on selector arm and press outer
rubber gaiter into body cutout.
Installation:
Insert rubber gaiter with arrow in direction of travel towards front.
Installation:
Press mount in area of retaining lugs into selector arm until it audibly
snaps into place.
Installation:
Grease selector lever ball.
Install selector lever in selector arm.
Align mount:
Arrows on mount in longitudinal axis of vehicle.
Retaining lugs of mount, transverse to direction of travel.
25 11 235 Replacing bearing bushes for shift arm

Remove shift arm.
Press out bearing bush (1).

Coat new bearing bush (1) with Circolight and then press into shift arm
until side edges of bush protrude uniformly.
Circolight, refer to BMW Parts Service.
25 11 041 Replacing bearing shell for shift lever

Remove shift lever
Detach mount from selector lever.Installation:

Grease ball joint.
Grease,
25 11 001 Replacing complete shift lever

Remove selector lever.
Remove vibration damper (if fitted).
Detach mount from selector lever.Installation:

Grease ball joint.
Grease,
Detach rubber gaiter from selector lever.
Installation:
Degrease selector lever (1).
Coat rubber bellows on inside of shaped section (2) with Circolight.
Circolight,
Pull rubber gaiter from above over selector lever and align. Arrow
(3) on rubber gaiter must point in direction of travel (A).
25 11 071 Replacing knob for shift lever
Note:
Do not twist knob during removal as this would cause the turning

Fit knob on selector lever, align and press on until it snaps
noticeably into place.
Note:
Illustration shows E46.
Installation:
Push rubber gaiter (1) down until groove (2) is fully exposed.
25 11 211 Replacing shift arm for shift-lever mount
Unflange propeller shaft from transmission and tie back to side on vehicle
underbody.
Remove selector lever.
Lever support bearing (1) out of mount.
Installation:
Insert support bearing (1) with arrow (2) facing upwards in holder.

Unclip cable from cross-member.
Release screws and remove cross-member (1).
Lower transmission slightly.
Lever out spring (1) with a screwdriver from lug (2) on housing.
Tilt spring upwards.
Remove bearing pin (1).Installation:

Grease,
Remove selector arm.

Detach support bearing (1) from selector arm.
Installation:
Grease bearing pin of selector arm.
Grease,
Fit support bearing (1) with opening (3) towards rear on selector
arm.
Replace bearing bush if damaged.
Press out bearing bush.
Coat new bearing bushing with Circolight and press into shift arm until
side ledges of bushing protrude uniformly.
Circolight,
25 11 245 Replacing shift arm support bearing

Necessary preliminary work (E60/E61/E63/E64 N62/N62TU/M57T2

only):
Remove reinforcement carrier.
Remove heat shields.
Lever out support bearing (1) from bracket.

Pull support off shift arm.
Installation:
Insert support bearing (1) with arrow (2) pointing up into retainer.
Detach support bearing (1) from shift arm.Installation:

Grease bearing pin of shift arm.
Attach support bearing (1) with opening (3) facing rear to shift arm.
25 11 101 Replacing shift rod

Remove heat shield
Remove transmission cross-member
Unflange propeller shaft from transmission
Detach locking clip (1).

Disconnect shift rod (2).
Installation:
Grease shift rod.
Make sure shims (3) are in correct position.
Important!
shift rod pin.
Unlock bearing pins (1) from selector arm in direction of arrow and
remove.Installation:
Grease bearing pin.
Lever spring washer (1) out of groove and push a little towards rear.
Press dowel pin (2) in direction of arrow out of shift rod joint and remove
shift rod (3).
Installation:
Grease ball of selector shaft.
Replace spring washer (1).
Installation:
Check rubber ring (1) in shift rod joint (2) and replace if necessary.
25 11 111 Replacing shift rod joint

Unflange propeller shaft from transmission.
refer to 26 11 000.
Detach locking clip.
Important!
shift rod pin.
Pull shift rod (1) out of shift rod joint (2) and remove
shims (3).Installation:
Grease shift rod pin (4).
Large contact surface of shims (3) must rest on shift rod joint (2).
Lever spring washer (1) out of groove and push a little towards rear.
Press dowel pin (2) upwards/downwards out of shift rod joint and remove
shift rod joint.
Installation:
Grease ball of selector shaft.
Replace spring washer (1).
Installation:
Check rubber ring (1) in shift rod joint (2) and replace if necessary.
25 16 175 Adjusting interlock cable
Note:
Do not turn handle when pulling off as this would shear off the
turning lock in the handle.
Pull off handle with a forceful tug.Installation:

Attach handle to selector lever.
Align handle and press on until it can be felt snapping into place.
Pull trim (1) out of center console.
Disconnect cable plug.
Installation:
Adjusting display slide of trim:
Press band (1) a little to one side.
Press adjuster (2) of display slide (3) against stop (4).
Position opening of trim (5) over opening of display slide (3).
Move preselector lever to ”N” (NORMAL) position.
Insert trim on preselector lever and install.
Move preselector lever to ”P” (PARK) position.
Display slide (3) is now adjusted.
Release screws.
Lever trim (1) out of center console, disconnect cable plugs (2 ... 3) and
remove trim (1).
Remove storage tray (1).
Release screws.
Pull support member (1) slightly out of center console.
Depending on equipment, press fitted switches (2) forwards out of
support member (1) and disconnect.
On rear side of support member (1), disconnect cable plug from cigarette
lighter and ashtray light.
Remove support member (1).
Move selector lever (1) to ”P” position (front stop of shifting gate).
Release screw (2). The cable (3) must remain easily movable axially in
the holder (4).
Move ignition key to ”zero” position and remove.
Press interlock lever (5) downwards as far as it will go.
Note:
Checking interlock adjustment:
Turn ignition key to ”ignition” position and then turn back to ”zero”
position.
Interlock lever (5) must rest on contact surface in selector lever (1).
If necessary, adjust interlock cable again.
25 16 ... Checking/adjusting Interlock/Shiftlock function
Adjusting interlock (with Steptronic):

the holder (4).
Adjusting interlock (without Steptronic):

the holder (4).
Checking interlock function:

a) Turn ignition key to ”ignition” position and then turn back to ”zero”
position and remove ignition key:
It should not be possible for the selector lever to be moved from
the ”P” position.
Interlock lever must rest on selector lever.
b) Turn ignition key to ”ignition” position, press foot brake:
It must be possible to select all selector lever positions.
c) Selecting all selector lever positions except ”P”:
In none of these positions should it be possible to turn the ignition
key back to the ”zero” position and remove it.
d) Move selector lever to ”P” position:
It must possible to turn the ignition key back to the ”zero” position
and remove it.
Checking shiftlock function:
a) Ignition on,
selector lever in ”P” or ”N” position,
press brake pedal:
selector lever must unlock.
b) Start engine,
press brake pedal,
engine speed greater than 2500 rpm:
selector lever must be locked in ”P” or ”N” position.
c) Ignition on,
move selector lever to ”R” position,
foot brake released:
In event of brisk shifting from position ”R” to ”D” and from ”D” to ”R”,
the selector lever must not be locked when position ”N” is
exceeded.
If it remains for more than approx. 0.5 secs. in position ”N”, the
selector lever must be locked.
d) Selector lever may only be locked in position ”P” or ”N”.
e) Driving speed greater than 5 km/h:
The selector lever must not be locked off.
25 16 056 Removing and installing / replacing shift tower (Steptronic)
Caution!
Do not disassemble new Steptronic shift tower.
Note:
Identifying features of new Steptronic shift tower:
1= Position, solenoid valve
2= Black plastic section
3= Aluminum section
Note:
Move selector lever to park position ”P”.
Brace clamping piece (1) and slacken nut (2).Installation:

Brace cable at hexagon (1) and release nut (2).

Pull cable out of holder.
Note:
Do not turn handle (1) when pulling off as this would shear off the
Pull off handle (1) with a forceful tug.

Installation:
Attach handle (1) to selector lever. Align handle (1) and press on
until it can be felt snapping into place.
Remove trim (2).
Installation:
Push rubber gaiter (1) downwards until groove (2) is fully exposed.
Disconnect plug connections 1 and 2.

Remove trim (3) with rubber gaiter.
Installation:
The lines must be correctly clipped into the retaining clips so as to
prevent damage (trapping of lines).
Release screws.
remove trim (1).
Release screws.

Disconnect cable from cigarette lighter on rear side of support member
(1).
Release screw (1) on interlock cable.
Remove cable plug (2) from fixture and disconnect.
Disconnect cable plugs (1).

Release screws and lift out shift tower (2) a little.
Unhook interlock cable.
Remove shift tower with cable.
Installation:
Adjust interlock cable and check interlock operation.
Installation:
Secure lines with cable ties.
32 32 170 Removing and installing/replacing interlock cable
Remove interlock cable from selector lever (version with interlock),

refer to MG 25.
Remove lower section of steering column trim,
refer to 32 31 020.
Open lock (1) and remove cable.Installation:

Lock (1) must snap into place.
25 16 056 Removing and installing/replacing shift tower
Move selector lever to ”P” (PARK) position.

Brace clamping piece (1) and slacken nut (2).Installation:

Brace cable at hexagon (1) and release nut (2).

Pull cable out of holder.
Note:

Disconnect cable plug.
Installation:
Release screws.
remove trim (1).
Release screws.

Detach cable plug from fixture and disconnect.
Release screw (1) and remove interlock cable (2) from interlock lever
(3).Installation:
Adjust interlock cable and check interlock operation.
Release screws and remove shift tower with cable.

25 16 130 Removing and installing/replacing shiftlock solenoid
Note:

Disconnect cable plugs.
Installation:
Release screws.
remove trim (1).
Release screws.
Detach cable plug from fixture and disconnect.
Release screws.
Lift shift tower (1) and remove acoustic insulation (4) towards bottom.
Lever out locking clip (3).
Withdraw shiftlock solenoid (2) from shift tower (1).
Installation:
The shiftlock solenoid (1) is secured against turning by a flat area on
the front journal.
25 16 130 Removing and installing/replacing shiftlock solenoid (Steptronic)
Note:
Do not twist handle during removal as this would cause the turning

Attach handle to selector lever. Align handle and press on until it
can be felt snapping into place.
Installation:
Push rubber gaiter (1) down until groove (2) is fully exposed.
Installation:
Push rubber gaiter (2) of panel (1) down and attach to selector lever
(4).
Connect cable plugs (3 and 5) to panel (1) and install panel (1) in
center console.
Remove trim (1) with rubber gaiter from center console.

Disconnect cable plugs (1 ... 2).
Unfasten screws.
Lift panel (1) out of center console, disconnect cable plugs (2 ... 3) and
remove panel (1).

Unfasten screws.
Remove support member (1) a little from center console.

Depending on equipment, press fitted switches (2) forward out of support
member (1) and disconnect.
On rear side of support member (1), disconnect power cable from
cigarette lighter. Remove support member (1).
Release cable plug (1) from holder and disconnect.
Release catches and remove protective cap (1) from shift bracket.
Unlock cable retainer (1) and detach.
Detach retaining plate (2).
Slide cable (3) as far as possible in direction of transmission tunnel.
Installation:
When installing shift cable, make sure rubber pad (2) is installed in
shift cable fork (1).
Press locking plate (1) in direction of arrow and turn shiftlock solenoid (2)
clockwise until shiftlock solenoid (2) can be withdrawn from shift tower
(3).Installation:
Insert shiftlock solenoid (2) into shift tower (3) and turn
counterclockwise until locking plate (1) snaps into place.
Installation:
Locking plate (1) of shiftlock solenoid valve (2) must be positioned
behind latch edge (3) (latched).
25 16 202 Replacing cable for gear selector lever
Remove shift bracket,

refer to 25 16 056.
Pull retaining plate (1) off cable.

Lift retaining disk (2) out of selector lever.
Installation:
Replace retaining disk (2).
Pull cable (1) out of ball shell (2) out of selector leverInstallation:
Replace ball shell (2).
Remove cable (1) with rubber sleeve (2) from shift tower.
25 16 061 Replacing handle for selector lever
Note:
Do not twist handle during removal as this would cause the turning

Fit knob on selector lever, align and press on until it snaps
noticeably into place.
Installation:
Push rubber gaiter (1) down until grooveÂ (2) is fully exposed.
26 11 ... Overview of propeller shaft with universal joint
0 General information
1 Complete propeller shaft 3 Centering mount
2 Flexible disk 4 Centre mount

26 11 000 Removing and installing complete propeller shaft (three-piece
propeller shaft)

26 1 040
Remove the heat shield (1).
Release ring nut (1) with special tool 26 1 040 several turns.
Installation note:
Tighten ring nut with special tool 26 1 040 .
Important!
To avoid buzzing sound after refitting the propeller shaft:
1. The flexible disc connection (1) on the front at the propeller
shaft must be marked in one plane with the flexible disc (2)
and the three-bolt flange (3) before removal.
2. During installation the three-bolt flange (3) must be forced
back together again with the flexible disc (2) in the same
position.
3. Replace ZNS bolts and self-locking nuts.
Release screws.
Installation note:
Replace ZNS bolts and self-locking nuts.
The screw connection must only be tightened using the nut.
Important!
To avoid complaints of humming: Before removing propeller shaft,
mark universal joint to drive flange of rear axle final drive.
Release screws.
Replace ZNS bolts.
Push the front propeller shaft (1) to the back.

Grip the propeller shaft and release screws on centre mount (1).
Unscrew nuts on rear centre mount (1).

Bend the propeller shaft downwards at the centre mounts.
Detach propeller shaft from transmission output flange and remove
downwards.
Installation note:
The deflection angle of the rear propeller shaft has been set in the
series assembly using discs (1).
The discs (1) are marked in the centre using a coloured plastic
insert and are secured at the threaded bolts and are more or less
non-detachable.
When installing the propeller shaft ensure, if necessary, that the
same discs (1) are re-installed.
Installation note:
Check centering bearing.
Replace damaged centring mount
Grease the centring.
26 11 000 Removing and installing complete propeller shaft - Version with
rear constant velocity joint -
Important!
position.
Release screws.
Installation note:
Now tighten the screw connection using the nut.
Remove constant velocity joint from rear axle differential.
Important!
Do not let propeller shaft fall into joints. The rubber cup is crushed or
the joint damaged, in particular at the constant velocity joint.

Installation note:
Remove the masking tape from the butyl tape on both sides.
Attach the butyl tape (1) to the centre mount (2) on the outside.
Butyl tape,
refer to BMW Parts Department.
Important!
Remove the butyl tape already installed on centre mounting.
Clean the bonding surface on centre mount and body.
Then wet the bonding surface on the body with mineral oil.
The wetting is necessary so that the adhesive butyl tape can gently
insert into the propeller shaft tunnel.
This prevents deformation of the butyl tape.
Installation note:
Press the centre mount (2) into the transmission tunnel.
Installation note:
Top up grease fill.
Grease,
refer to BMW Parts Department.
Withdraw constant velocity joint (1) up to limit position.

Coat sealing surfaces of constant velocity joint and drive flange with
grease.
Replace gasket (2).
Installation note:
Attach propeller shaft with pulled-apart constant velocity joint to drive
flange of rear axle final drive.
Important!
Do not compress constant velocity joint during assembly because
the grease filling can force away the sealing ring, leading to a
leakage from the constant velocity joint.
Alternately tighten 2 opposing nuts to draw constant velocity joint
evenly into the drive flange.
Then secure the other nuts.
Installation note:
Check centring mount (4).
Replace damaged centring mount.

Apply Molykote Longterm 2 grease to centring mount.
26 11 000 Removing and installing propeller shaft (cardan universal joint)
completely

26 1 040

Release ring nut (1) with special tool 26 1 040 several turns.Installation
note:
Tighten ring nut with special tool 26 1 040 .
Important!
position.
Release screws.
Installation note:
Grip mounting bolts of flexible disc at gearbox flange at bolt
head and tighten down at nut.
Important!
To avoid complaints of humming:
Before removing propeller shaft, mark universal joint to drive flange
of rear axle final drive.
Reinstall joint in this position.
Release screws.
Replace ZNS bolts.
Push rear propeller shaft (1) forwards.

Bend propeller shaft downwards at centre mount (1).
Detach propeller shaft from transmission output flange and remove
downwards.
Installation note (excl. E46 Compact and Z4):

Remove the masking tape from the butyl tape on both sides.
Attach the butyl tape (1) to the centre mount (2) on the outside.
Butyl tape: BMW Parts Department
Important!
(excl. E46 Compact and Z4)
Remove the butyl tape already installed on centre mounting
Clean the bonding surface on centre mount and body
Then wet the bonding surface on the body with mineral oil
The wetting is necessary so that the adhesive butyl tape can
gently insert into the propeller shaft tunnel.
This prevents deformation of the butyl tape.
Installation note:
Press the centre mount (2) into the transmission tunnel.
Installation note:
Check centering; if necessary, replace damaged centering.
Grease centring mount.
Grease: BMW Service Operating Fluids.
26 11 090 Removing and installing/replacing front centring mount for
propeller shaft

00 5 500
11 1 310
11 2 030

Completely fill centring bore hole (1) with viscous grease.

Drive special tool 11 1 310 with a plastic hammer into centring bore hole.
The centring bearing (1) is forced out of the propeller shaft by the
pressure on the grease filling.
If necessary, top up grease repeatedly.
Note:
To drive out the bearing, you can also fill the centring bore hole with
water instead of grease.
Installation note:
Remove grease/water from mount bore.
Drive in centring mount (1) with special tools 11 2 030 and 00 5 500 into
propeller shaft (observe protrusion).
Grease: BMW Service Operating Fluids.
Installation note:
Observe protrusion A = 4+2 mm of centring (1).
26 11 051 Replacing flexible disc for propeller shaft

Remove propeller shaft from transmission and centre mount
Note:
To protect universal joints, tie back propeller shaft in area of centre
mount.
Release screws and remove flexible disc (1) from propeller shaft.
Installation note:
Arrows (3) on circumference of flexible disc must point to
flange arms (2).
Grip mounting bolts of flexible disc at propeller shaft flange at
nut and tighten down at bolt head.
Installation note:
Check centring, replace damaged centring.

26 12 002 Replacing both complete propeller shaft center mounts (three-part
propeller shaft)
Remove propeller shaft,

refer to 26 11 000.
Front center mount:

Note:
The propeller shaft is balanced. The front and middle propeller
shafts must be reassembled in the same position.
Mark front propeller shaft (2) and middle propeller shaft (1) in one plane.
Pull propeller shaft apart.
Remove retaining ring (1).
Take off dust cover (1).

Install special tool 00 7 500 between center mount (1) and universal joint
(2).
Using a hydraulic press, force center mount (1) off propeller shaft (2).
Force new center mount (1) onto propeller shaft. Collar (2) must point to
special tool 23 1 160.
Drive center mount firmly home with special tool 23 1 160.
Insert dust cover (1) in center mount.

Install new snap ring (1), with plate to dust cover (2).
Screw threaded ring (1) off propeller shaft; if necessary, use special tool
26 1 040 to provide assistance.
If necessary, insert new clamping ring (1) in threaded ring (2).
Force threaded ring (1) onto shaft (2).

Grease longitudinal splines of shaft (2) evenly.
For grease, refer to BMW Service Operating Fluids.
Observe markings and force front propeller shaft (3) onto shaft (2)
(markings must be flush).
Screw down threaded ring (1) with front propeller shaft (3) until hand-tight.
Rear center mount:
Note:
The propeller shaft is balanced. The middle and rear propeller shafts
must be reassembled in the same position.
Mark middle propeller shaft (1) and rear propeller shaft (2) in one plane.
Release screw (1) and pull propeller shaft apart.

Clean thread in propeller shaft and thread of screw.
Position special tool 00 7 500 behind center mount (1).
Using a hydraulic press, force center mount (1) off propeller shaft.
Force new center mount (1) onto propeller shaft (3). Collar (2) must point
to propeller shaft (3).
Drive center mount (1) firmly home with special tool 23 1 160.
Observe marking and force universal joint (1) of rear propeller shaft onto
middle propeller shaft (2).
Install screw (3) with Loctite 273 locking varnish.
Tightening Torque,
26 12 001 Replacing complete propeller shaft centre bearing (constant-
velocity joint)

00 7 500
24 0 090
24 1 050
33 1 307
Important!
Propeller shaft is balanced as a unit.
Mark front propeller shaft relative to rear propeller shaft with paint stick.
Marking by means of engraving which causes surface damage (e.g.
centre mark) is not permitted.
Release screw (1).

Installation:
Thread free from grease.
When pushing shaft together, make sure that markings match up.
Insert bolt (1) with thread-locking liquid,
Remove shim and dust gaiter.

Pull off centre bearing with special tool 00 7 500 / 33 1 307 and
commercially available puller.
Drive new centre bearing firmly home with special tool 24 0 090 or
24 1 050 .Note:
Bearing inside diameter 30 mm, use special tool 24 0 090 .
Bearing inside diameter 35 mm, use special tool 24 1 050 .
26 12 001 Replacing complete propeller shaft centre mount

00 7 500
23 1 160
26 1 040

Note:
The propeller shaft is balanced. The front and rear propeller shafts
Mark front propeller shaft (1) and rear propeller shaft (2) in one plane.

Install special tool 00 7 500 between center bearing (1) and universal
joint (2).
Using a hydraulic press, force center bearing (1) off propeller shaft (2).
Force new center bearing (1) onto propeller shaft. Collar (2) must point
to universal joint (3). Drive centre mount firmly home with special tool
23 1 160 .
Install new snap ring (1), with plate to bearing.

Screw threaded ring (1) off propeller shaft. If necessary, use special tool
26 1 040 as an aid.

Grease longitudinal splines of shaft (2) uniformly.
Observe markings and force rear propeller shaft (3) onto shaft (2)
Screw down threaded ring (1) with propeller shaft (3) until hand-tight.
26 12 011 Replacing deep-groove ball bearing in propeller shaft center
mount (three-part propeller shaft)

refer to 26 11 000.
Front center mount:

Note:
The propeller shaft is balanced. The front and middle propeller
shafts must be reassembled in the same position.
Mark front propeller shaft (2) and middle propeller shaft (1) in one plane.
Remove retaining ring (1).
Remove dust cover (1).

Install special tool 00 7 500 between center mount (1) and universal joint
(2).
Using special tool 23 1 160, press deep-groove ball bearing out of center
mount (1).
Coat rubber-coated bearing seat of center mount with Circolight.

Using special tool 33 3 202/ 33 3 203, press new deep-groove ball
bearing (1) into center mount (2).
Force center mount (1) onto propeller shaft. Collar (2) must point to
Drive center mount firmly home with special tool 23 1 160.
Insert dust cover (1) in center mount.
Install new snap ring (1), with plate to dust cover (2).
Screw threaded ring (1) off propeller shaft; if necessary, use special tool
26 1 040 to provide assistance.

Grease longitudinal splines of shaft (2) evenly.
For grease, refer to BMW Service Operating Fluids.
Observe markings and force front propeller shaft (3) onto shaft (2)
Screw down threaded ring (1) with front propeller shaft (3) until hand-tight.
Rear center mount:

Note:
The propeller shaft is balanced. The middle and rear propeller shafts
Mark middle propeller shaft (1) and rear propeller shaft (2) in one plane.
Release screw (1) and pull propeller shaft apart.

Clean thread in propeller shaft and thread of screw.
Position special tool 00 7 500 behind center mount (1).
Using a hydraulic press, force center mount (1) off propeller shaft.
Using special tool 23 1 160, press deep-groove ball bearing out of center
mount (1).
Coat rubber-coated bearing seat of center mount (2) with Circolight.

Using special tool 33 3 202/ 33 3 203, press new deep-groove ball
Force center mount (1) onto propeller shaft (3). Collar (2) must point to
propeller shaft (3).
Drive center mount (1) firmly home with special tool 23 1 160.
Observe marking and force universal joint (1) of rear propeller shaft onto
middle propeller shaft (2).
Install screw (3) with Loctite 273 locking varnish.
Tightening Torque,
26 12 011 Replacing grooved ball bearing in center mount of propeller shaft

00 7 500
23 1 160
26 1 040
33 3 202
33 3 203

Note:
The propeller shaft is balanced. The front and rear propeller shafts
Mark front propeller shaft (1) and rear propeller shaft (2) in one plane.

Install special tool 00 7 500 between center bearing (1) and universal
joint (2).
Using special tool 23 1 160 , press deep-groove ball bearing out of

center mount (1).
Coat rubber-coated bearing seat of center mount (2) with Circolight.

Using special tool 33 3 202 / 33 3 203 , press new deep-groove ball
Force center mount (1) onto propeller shaft. Collar (2) must point to
universal joint (3). Drive center mount firmly home with special tool
23 1 160 .
Install new snap ring (1) with plate to mount.
Screw threaded ring (1) off propeller shaft. If necessary, use special tool
26 1 040 as an aid.

Grease longitudinal splines of shaft (2) uniformly.
Observe markings and force rear propeller shaft (3) onto shaft (2)
Screw down threaded ring (1) with propeller shaft (3) until hand-tight.
Headaches
Dizziness
Stomach aches
Vomiting
Diarrhoea
Cramps/fits
Unconsciousness

or mugs)
First aid measures:

immediately.
Danger of injury!
Impaired sight

First aid measures:

Warning!
Recycling:

ground.
Headaches
Dizziness
Stomach aches
Vomiting
Diarrhoea
Cramps/fits
Unconsciousness

or mugs)
First aid measures:

immediately.
31 00 ... Front axle + steering: wheel/chassis alignment check must be
carried out after the following work
A wheel/chassis alignment check must be carried out after the following work:
Release of following screw/bolt connections:
Steering gear to front axle carrier
Support bearing to body (if centering pin is missing)
Tie rod end to tie rod
Replacement of following parts:

1. Front axle carrier
2. Steering gear
3. Control arm
4. Support bearing (if centering pin is missing)
5. Steering knuckle
6. Tie rod end
7. Tie rod
31 ... . Front axle overview
0 Safety precautions and general

information
1 Thrust bearing 8 Power steering gear

2 Coil spring 9 Stabilizer/stabilizer suspension
3 Spring strut shock absorber 10 Front axle support
4 Control arm 11 Steering knuckle/wheel bearing
4.1 Bracket/rubber mount for control arm 12 Stabilizer link
5 Brake disk Testing/adjustment work
6 Brake caliper Troubleshooting (front axle/shock absorber)
7 Tie rod
31 00 ... Information on replacing shock absorbers
Situation:
When a shock absorber is faulty on one side (leaking, noises, limit values exceeded on the shock tester),
often both shock absorbers on the axle in question are replaced.
Effect:
This is not necessary for technical reasons and causes the manufacturer not to recognize the unnecessarily
removed shock absorbers as defective parts. Unnecessarily high costs for the customer can be avoided by
replacing the shock absorber on one side only.
Procedure:
If one shock absorber is damaged, it is only necessary to replace both shock absorbers when the car has
driven in excess of 80 000 km.
Exception: On all M‐GmbH models, when a limit value is exceeded on one side, it is still necessary always to
replace both shock absorbers on the relevant axle.
Information on replacing shock absorbers on E65/E66 models with EDC before production 03/07
Component version (build date) before 03/07:
Both shock absorbers must be replaced (refer to BMW Parts Department information) (See Note BMW
Parts Department)
Component version (build date) after 03/07:
The shock absorbers can be replaced again individually.
If in doubt, always replace both shock absorbers.
31 00 ... Instructions (chassis components made of aluminium)
Due to the chemical and corrosion characteristics of aluminium, always comply with the following points when
handling aluminium components:
- Do not bring into contact with battery acid!
- Do not clean with wire brushes made of brass or iron! Always use wire brushes with stainless steel bristles!
- Do not expose to flying sparks when grinding/separating! Cover components!
- Do not strike with steel welding splashes! Cover components!
- Do not expose to temperatures > 80 Â°C, even for brief periods! Temperatures in paint facilities do not have
the same impact
31 .. .. Layout of spring strut shock absorber
1 Spring strut shock absorber 10 Upper spring pad

2 Lower spring pad 11 Thrust bearing
3 Coil spring 12 Dust sleeve
4 Auxiliary spring 13 Thrust washer/shim
5 Wheel arch 14 Rubber gaiter
6 Upper spring plate
7 Centering pin
8 Grease cap
9 Nut
31 00 Mobile table lift
Warning!
Danger of injury!
Before beginning work, position table lift with the lower frame
securely on the floor.
Danger area around mechanism below platform.
Do not reach into or step into the danger area.
Note permissible bearing capacity of table lift.
Mount load centrally (danger of tipping) and secure against
shifting.
Follow the operating instructions from the equipment manufacturer.
The mobile table lift is used for collision repairs and when removing large
engines.
Adaptations for mounting front

axle with engine and
transmission.
No. For mounting swivel

10 bearing with brake disc
No. Retaining element for
20 adjustable fixture
No. Adjustable fixture
30
No. Distance pin 40 x 160 mm
40
50
60
No. Fixture with U-profile
70
No. Plate fixture Ø=100 mm
80
Release star knob screw on
working plate (B) of table lift; the
working surface (B) can be
extended by approx. 310 mm.
Release all push-pull clamps and
the working plates can be
shifted by approx. 20 mm.
Working plate (A and B) can be
raised and lowered by 3° on the
long side and by 5° on the
transverse side.
Working plate (A and B) is
subdivided by a coordinate
system and a possible
installation position is
recommended in the respective
repair manual.
Important!
Follow the operating instructions from the equipment manufacturer.
31 00 ... Notes
Accident-related repairs:
Read and comply with Information on replacing steering gear after accident damage.
If the control arm or tie rod is bent, it is essential for safety reasons to check the spring strut piston rod for
straightness.
31 00 ... Notes on repairing threads
Important!
Install Helicoil thread inserts so that they are flush with the original
thread.
Note:
Damaged threads in engine support may be repaired with Helicoil thread
inserts. Comply with the procedure described in the example.
Procedure:
1. Create a clean core hole; if necessary, drill out screw remnants
2. Create locating thread for Helicoil thread insert
3. Pick out Helicoil thread insert in accordance with the table and screw
into the locating thread until flush with the original thread
4. Break drive pin and remove
31 00 ... Notes on wheel bearing replacement following accident
damage
Wheel bearing facts:
In the event of accidents or driving conditions similar to accidents, shock-like loads to the wheel bearing units
can cause slight damage to the bearing track. Despite initial running without noise, with continued use, this
results in later noise generation at the wheel bearing.
Procedure:
The wheel bearing must be replaced on the damaged side of the axle if one or several of the following points
apply:
Visible or noticeable damage to the wheel bearing
Rolling noises, radial/lateral runout on the wheel bearing
Permissible tolerance for the wheel alignment is exceeded and no longer adjustable without the
exchange of additional components
Damage, permanent deformation or fractures to:
Wheel rims (major damage) and simultaneous negative result for wheel alignment
Spring struts, swivel bearings, wheel carriers
Wishbones
Struts or trailing links or anti-roll bar with this function
Body-side screwing/attachment points for wheel guide/control components
Track rods
Steering box fixtures
This guideline is binding for all accident repairs to BMW, MINI and Rolls-Royce vehicles!
Warning!




Risk of damage!
Danger of injury!
Impaired sight

First aid measures:

Warning!
Recycling:

ground.
31 10 000 Removing and installing complete front axle (with spring strut
shock absorber)

Secure engine in installation position
Remove underbody protective plate
Remove reinforcement/reinforcement plate
Remove lower steering spindle from power steering gear
If necessary, disconnect plug connection from ride-height
sensor
Remove and tie back brake caliper on both sides
Disconnect plug connection for pulse generator
Remove stabilizer link from stabilizer
Remove both brackets for control arm from engine carrier
Remove spring strut on both sides from spring strut dome
Important!
Guide spring struts with your hand when lowering and raising in
order to avoid damaging the wheel arches.
After lowering, the spring struts must be aligned to the front
axle carrier and secured in such a way that the ball joints of the
control arms and tie rod ends are not damaged.
Check sensor head and line from pulse generator prior to
installation for external damage, replacing if necessary.
Support front axle carrier, release from engine carrier and carefully lower
with spring struts.
After installation:
Carry out wheel alignment check if a spring strut with support
bearing was or has been installed without centering pin.
Carry out steering angle sensor adjustment
31 11 005 Removing and installing/replacing reinforcement (cruciform)
Important!
Observe safety instructions for raising the vehicle!
Driving without the reinforcement fitted is not permitted!
Reinforcement must not rest on bracket with rubber mount of
control arm!
Remove splash guard, if necessary.

Release bolts (2).
Release bolts (1); if necessary, remove washers.
Remove reinforcement.
Installation:
If a 66 mm dia. control arm rubber mount is fitted, a washer (S) must
be fitted at each bolt (1) between reinforcement (3) and engine
carrier (4).
Important!
If necessary, bend heat shield away from reinforcement.
Diesel engines:
If necessary, recondition (cut) rear left assembly underside
protection in order to create a gap to reinforcement. If the required
change is not made, the assembly underside protection will tense
up and loosen during driving operation!
31 11 506 Lowering/raising front axle carrier

Remove lower steering spindle from power steering gear
sensor
After installation:
Important!
Pay attention to power steering hoses and lines when lowering and
raising. Hoses/lines must not be kinked/tensioned/bent!
Support front axle carrier in area (A) with workshop jack.

Release screws (1, 2).
Lower front axle carrier.
Installation:
Check threads for damage; if necessary, repair with Helicoil thread
inserts.
Tighten down first screws (2) and then screws (1).
31 11 005 Removing and installing/replacing reinforcement (cruciform)
Important!
Observe safety instructions for raising the vehicle!
Driving without the reinforcement fitted is not permitted!
Reinforcement must not rest on bracket with rubber mount of
control arm!
Remove splash guard, if necessary.

Release bolts (2).
Release bolts (1); if necessary, remove washers.
Remove reinforcement.
Installation:
If a 66 mm dia. control arm rubber mount is fitted, a washer (S) must
be fitted at each bolt (1) between reinforcement (3) and engine
carrier (4).
Important!
If necessary, bend heat shield away from reinforcement.
Diesel engines:
If necessary, recondition (cut) rear left assembly underside
protection in order to create a gap to reinforcement. If the required
change is not made, the assembly underside protection will tense
up and loosen during driving operation!
31 11 001 Replacing front axle carrier

If necessary, remove ride-height sensor with bracket from front
axle carrier
Remove control arm from front axle carrier
Remove power steering gear from front axle carrier and tie up
After installation:
Perform chassis alignment check
Support front axle carrier, release from engine carrier and carefully lower.
Remove engine mounts on both sides, if necessary with vacuum line
from front axle carrier.
Take front axle carrier down and set down on a suitable surface.
31 12 023 Measuring play of wheel control joints

31 1 060
31 1 071
31 1 079
Test apparatus (31 1 060 ):

1. Slide (31 1 061)
2. Measuring electronics (31 1 062)
3. Magnetic retainer (31 1 063)
4. Evaluation electronics (31 1 064)
5. Magnetic retainer (31 1 065)
6. Hook wrench (31 1 066)
7. Measuring clip (31 1 067)
Note:
In warranty case:
Connect DIS Tester
Select ”Service functions”
Select ”Check play of wheel guide joints”
Work through test module according to test schedule
Print out diagnosis report
M3:
If necessary, clean moulded disc 31 1 071 .
Stick adhesive dot 31 1 079 onto moulded disc 31 1 071 .
Fit moulded disc 31 1 071 on control arm (below ball joint).
On vehicles with 15” rims, the front wheels must be removed if
necessary.
Important!
Make sure magnetic retainer (1) is correctly seated.
Place magnetic retainer (1) on control arm (2) below ball joint or on
moulded disk 31 1 071.
Important!
Measuring clip must not contact the control arm.
Fit measuring clip (1) on threaded stem (2) of ball joint and screw down
with locating screw (3).
Press button on evaluation electronics.
Note:
The device performs a self-test.
Both LEDs flash, then the red LED lights up permanently.
Move slide with measuring electronics upwards until green LED lights up.
Note:
Gap (A) between measuring electronics and magnetic retainer must be
approx. 5-7 mm.
Then secure slide with clamping screw (1).

Press evaluation electronics button for approx. 2 seconds until the green
LED flashes.
Note:
The device is now calibrated and ready for measuring.
1.) Test:
Set torque wrench to 60 Nm.
Introduce a force with hook wrench (1) in the direction shown until
torque is obtained.
Read off test result:

Red LED flashes: Joint must be replaced
Green LED flashes: Carry out 2nd test
2.) Test:
Reposition hook wrench.
Introduce a force with hook wrench (1) in the direction shown until
torque is obtained.
Read off test result:

Red LED flashes: Joint must be replaced
Green LED flashes: Joint must not be replaced
31 12 000 Removing and installing left or right control arm

11 7 360
32 3 090

Remove front wheel
Only on right side:
If necessary, remove retaining angle for jointed rod of
ride-height sensor from control arm
Unfasten nut.
Press control arm off steering knuckle with special tool 32 3 090 .
Installation:
Keep journal on ball joint and bushing in steering knuckle clean and free
from oil and grease.
Unfasten nut.
Strike off control arm support joint with plastic hammer.
Installation:
Keep journal on support joint and bushing in front axle carrier clean and
free from oil and grease.
Force ball joint upwards with a workshop jack and base 11 7 360 ; this
makes it easier to tighten down the nut.
Remove bracket for control arm on engine carrier and remove control
arm.
31 12 049 Removing and installing/replacing both brackets for control arm

00 7 500
31 2 151
31 2 152
31 2 153
31 2 154
31 2 156
31 2 157
31 2 158
Important!
If a bracket is replaced, a new bracket must also be installed on the
other side!

If necessary, remove heat shield(s).
Unfasten screws.Installation:
inserts.
Replace screws.
Punch-mark centre of control arm.

Composite parts of special tool 00 7 500 .
If necessary, remachine special tool 31 2 151 (see drawing).
Detach bracket with special tools 00 7 500 and 31 2 151 from control
arm.Important!
Never re-use a rubber mount pulled off control arm. Rubber-coated
inner sleeve is destroyed when pulled off dry.
Important!
Control arms with pin shape (A) must be replaced!
Only control arm with pin shape (B) may be reinstalled!
Mark out measurement (A) at bottom at control arm pin.
A = 290.9 ± 1 mm
Installation:
Outer edge (B) of rubber mount must be flush with marked
measurement (A).
Important!
If measurement (A) is not strictly adhered to, this will result in
impaired vehicle handling and early rubber mount wear!
Coat control arm pin and rubber mount bushing with soap water.
Mixture ratio: 1 part soap to 20 parts water.
Ensure positive locking (1) of bushing and control arm pin.
The larger diameters of the bores (2) point to the engine carrier.
Control arm without openings:

Secure special tools 31 2 156 and 31 2 158 to control arm until hand-tight.
Install new bracket with special tools 00 7 500 and 31 2 152 , 31 2 154 ,
31 2 157 onto control arm up to applied marking.
Relieve tension on special tool. Check position of rubber mount to
marking (measurement A) and correct if necessary.
Control arm with openings:
Attach special tool 31 2 153 with extensions (1) from puller set to control
arm opening.
Install new bracket with special tools 00 7 500 and 31 2 152 , 31 2 154 ,
31 2 157 onto control arm up to applied marking.
Relieve tension on special tool. Check position of rubber mount to
marking (measurement A) and correct if necessary.
After installation:
Check freedom of movement of other components to bracket for
control arm
If necessary, bend back heat shield and cut assembly underside
protection
31 12 001 Replacing left or right control arm
Warning!
If a control arm with openingsÂ (B), see graphic below, is deformed
and replaced, the front axle carrier must also be replaced!
The bore for the ball joint in the front axle carrier is deformed/oval.
Note:
Checking wheel control joints:
Refer to Measuring play of wheel control joints.
Build date from 07/1999: Important!

Control arms without openings are no longer available as new parts!
If one control arm is damaged, both control arms must be replaced
with control arms with openings! Fitting one control arm of each type
is not permitted!
A Control arm without opening
B Control arm with openings
Important!
Fit control arm with same identification only.
Important!
Before installing a new control arm, it is essential to derust the stub
axle in the area of the contact face of the rubber sleeve.
Remove control arm.

Replace brackets/rubber mounts on both control arms.
After installation:
31 21 080 Replacing (removing and installing) left or right steering knuckle

31 2 200

Remove brake disk
Remove pulse generator from steering knuckle
Replacement only:
Remove wheel bearing
Remove tie rod end from steering knuckle
If necessary, remove control rack of ride-height sensor from
control arm
Remove control arm from steering knuckle
Installation:
Support steering knuckle from underneath using a workshop jack.

Release bolt and remove with bracket towards front.
Expand steering knuckle with special tool 31 2 200 .
Lower workshop jack and remove steering knuckle.
Installation:
Keep press fit of steering knuckle and spring strut in lower area clean and
free from oil and grease.
Spread steering knuckle with special tool 31 2 200 , align by means of
gap to positioning pin (1) on back of spring strut and raise as far as it will
go.
Replacement:
Modify brake guard plate.
After installation:
Replacement only:
31 21 180 Replacing bearings (wheel hub) for front wheel

31 2 080
31 2 110
33 2 116
33 2 160
33 2 201
33 4 200
33 4 401
33 4 402
33 4 406
Overview of bearing arrangement:

1. Wheel hub
2. Collar nut
3. Axle stub
4. Dust guard plate
5. Sealing cap

Remove brake disk
Remove pulse generator from steering knuckle
Important!
Removing bearing:
Remove sealing cap with screwdriver/chisel.
Release collar nut with cross-cut chisel and remove with special tool
31 2 080 .
Force drive flange with special tools 33 2 116 / 33 2 201 , 33 2 160 ,

33 4 200 and five wheel bolts out of wheel bearing.Note:
Rounded inside edge of special tool 33 2 160 must point to drive flange.
Important!
Bearing must not be reused after it has been detached!
Detaching bearing inner race:

Attach special tools 33 4 406 and 33 4 401 to bearing inner race and
tension until special tool can still just be turned.
Detach bearing inner race with special tool 33 4 402 .
Installing bearing:
If necessary, install brake guard plate.
Fit new dust guard plate (2).
Screw in guide sleeve (1) of special tool 31 2 110 over full length of
thread.
Draw on bearing.
Replace collar nut, oil slightly and tighten down with special tool 31 2 080 .
Secure collar nut by peening on flat areas of output shaft.
Replace sealing cap. Coat edge (mounting face to wheel hub) over
entire extent with sealing compound (refer to BMW Parts Service) and fit
sealing cap.
Situation:
Effect:
Procedure:
Parts Department)
31 31 ... Instructions on handling the BMW spring tensioner
Note:
The following description refers exclusively to the spring tensioner
currently sold by BMW.
Older spring tensioners may only be used in the model series mentioned
in the relevant repair instructions if there are no corresponding spring
holders for the current spring tensioners.
The spring tensioner may only be used in conjunction with the relevant
BMW repair instruction (latest edition).
Warning!
Observe the following instructions to avoid any risk of injury by the
coil springs.
1. Prior to each use, check the special tools for defects,
modifications and operational reliability.
2. Damaged/modified special tools must not be used!
3. No changes or modifications may be made to the special
tools!
4. These special tools are intended solely for the purpose of
tightening and relieving cylindrical and tapered suspension
springs.
5. Keep special tools dry, clean and free of grease.
6. Impact screwdrivers may not be used!
7. Do not compress coil spring to full extent.
8. Observe manufacturer's instructions.
The corresponding spring strut must always be removed completely

beforehand.
The following special tools must be used:
Basic tool 31 3 341

Depending on the model, appropriate spring holders (1) and protective
inserts (2) from special tool kits 31 3 350, 31 3 380 and 31 3 360 (refer to
repair instruction of relevant model)
Basic handling:
Clamp basic tool 31 3 341 at strip (1) in vice.
The protective inserts protect the sensitive springs against damage.

Therefore always use the spring holders with the appropriate protective
inserts.
On some vehicle model series (e.g. E60), there is the risk of the spring
turning during removal/installation together with the protective insert out
of the spring holder. This poses a danger to life!
In this case, the protective insert must not be fitted with the spring
holders.
Reference is clearly made to this in the corresponding repair instruction.
Spring holders must each be inserted from chamfer (1) into the basic
tool.
Depending on the model, feed the corresponding spring holders (here
31 3 352 and 31 3 354) and if necessary together with the protective
inserts (here 31 3 367 and 31 3 354) into the fixtures (2) of basic tool
31 3 341 (1) and lock in place.
The correct spring holders for the corresponding models are specified in
the repair instruction.
Locking pins of fixture (2) must be felt and heard to snap into place.
Before inserting spring tensioner, clean spring to remove coarse

contamination.
Never tighten or untighten special tools with an impact screwdriver.
Lay upper turn of coil spring into corresponding spring holder.
Turn spring tensioner and position spring strut so that the last turn is
flush with the corresponding spring holder, feed spring into spring holder
and gently tighten spring tensioner.
Model-specific tensioning specifications are given in the relevant repair
instruction.
Important!
In some case, a special spring holder (here 31 3 381) may also be
used. Reference is made to this in the corresponding repair
instruction.
Warning!
Check correct seating of spring in spring tensioner again
When tensioned, the spring coils must rest completely in the spring
retainer recess.
Compress coil spring until stress on piston rod is relieved.Warning!

Do not compress spring to full extent.
There should always be a minimum gap (A) between the spring
turns. Gap may be ”0” if both these spring turns do not rest on each
other all round.
Release nut only when tension is relieved on piston rod.
Screw connection of support bearing to piston rod must not be
released with impact screwdriver!
Depending on the model, release nut with corresponding special
tool (here 31 2 210) (refer to repair instruction), gripping the piston
rod in the process:
Vehicles without EDC: internal hexagon
Vehicles with EDC: external hexagon

7 Centering pin
8 Grease cap
9 Nut
31 31 000 Removing and installing complete left or right spring strut shock
absorber
Important!
If the centring pin is missing from the support bearing, the position of
the threaded bolts to the wheel arch must be marked so that the
original camber is approximately maintained.
Only one nut may ever be released for marking.
Installation note:
must be replaced.
must be replaced.

Removing steering stub
Removing anti-roll bar link on front spring strut
Note:
Read and comply with Information on replacing shock absorbers.
Centring pin missing: Make position of threaded bolt in relation to wheel

arch.
Secure spring strut against falling out.
Unscrew nuts.
Remove spring strut downwards out of wheel arch.
Installation note:
Align spring strut using centring pin (1) for bore hole (2) in wheel arch, or
stud bolts for the marks on the wheel arch and push upwards.
Tighten nuts.
After installation:
bearing was or has been installed without centering pin.
31 31 031 Replacing front left or right spring strut shock absorber

31 2 210
31 3 340
31 3 341
31 3 354
31 3 355
31 3 356
Important!
When replacing shock absorber/spring strut, renew auxiliary
damper!
Warning!
Before using the special tool 31 3 340 take care to read through
the Owner's Handbook!
All the safety information and instructions contained in the Owner's
Handbook must be strictly observed!
Failure to observe these safety precautions and instructions
increases the risk of serious physical injury, damage to your health
and damage to property and equipment!
Important!
1. Prior to each use, check the special tools for defects,
modifications and operational reliability.
2. Damaged/modified special tools must not be used!
3. No changes or modifications may be made to the special
tools!
4. These special tools are intended solely for the purpose of
tightening and relieving cylindrical and tapered suspension
springs.
5. Keep special tools dry, clean and (down to the spindle) free
from grease.
6. Impact screwdrivers are prohibited!
Risk of damage inside the shock absorber!
7. Do not compress coil spring to full extent.

Remove front spring strut.
Removing:
Clamp special tool 31 3 341 with guide (1) in vice.
Fit special tool 31 3 354 and 31 3 355 from above on special
tool 31 3 341 until retaining bolts (2) can be felt and heard to snap into
place.
Check seating of special tools 31 3 354 and 31 3 355 , correct if
necessary.
Clean coil spring to remove heavy contamination.

Position centring ring 31 3 356 on top spring cup.
Hold coil spring and top spring plate with special tools 31 3 354 ,
31 3 356 and 31 3 355 .
Twist spring strut until end of coil spring (1) is flush with end (2) of special
tool 31 3 355 .
Warning!
Special tool 31 3 354 and centring ring 31 3 356 must rest correctly
on the upper spring cup!
Bottom coil of coil spring must rest completely in recess of special
tool 31 3 355 !
Compress coil spring until stress on piston rod is relieved.

Take off cap.
Release nut with special tool 31 2 210 (grip piston rod in the process).
Remove support bearing, if necessary with adapter for rough road
package and/or reinforcement.
Remove dust boot and shim.
Remove shock absorber with auxiliary damper, gaiter and lower spring
pad sideways from tensioned coil spring.
Impact screwdrivers are

prohibited!
Risk of damage inside
the shock absorber!
If necessary, remove auxiliary damper (1) with gaiter (2) and spring
pad (3) from shock absorber.
Relieve tension on coil spring.

Remove coil spring and spring cup from special tools 31 3 354 , 31 3 356
and 31 3 355 .
Assembly:
Check spring pad (1) for damage, replace if necessary.
Fit centring ring 31 3 356 and spring pad (1) with spring cup (2) on coil
spring.
Note:
End of coil spring must be positively aligned to spring pad (1).
Hold coil spring and spring plate with special tools 31 3 354 , 31 3 356
and 31 3 355 .
Twist coil spring until lower end of coil spring (1) is flush with end (2) of
Warning!
Do not compress coil spring to full extent.
Special tool 31 3 354 and centring ring 31 3 356 must rest correctly
on the upper spring cup!
Bottom coil of coil spring must rest completely in recess of special
tool 31 3 355 !
Tension coil spring.
Check auxiliary damper (1), gaiter (2) and spring pad (3) for damage,
replace if necessary.Note:
Recesses on spring cup and spring pad (3) must be flush.
Insert shock absorber in tensioned coil spring.

Attach shim and dust boot to piston rod.
Check support bearing for damage, replace if necessary.
Attach support bearing if necessary with adapter for rough road package
and/or reinforcement to piston rod.
Replace nut and tighten down with special tool 31 2 210 (grip piston rod
in the process).
Fit cover cap.
Impact screwdrivers are

prohibited!
Risk of damage inside
the shock absorber!
Important!
Spring pad (1) must rest positively on spring cup (2)!
Upper end of coil spring must rest on stop of spring pad (1)!
Important!
Lower coil of coil spring must rest positively on spring cup!
Relieve tension on coil spring.

Check installation position of gaiter, correct fold if necessary.
After installation:
bearing was or is installed without centring pin.
31 33 001 (Removing and installing) replacing front left or right spring strut
support bearing
Installation note:
must be replaced.
must be replaced.
Note:
Procedure is described in the document ”Replacing front left or right
spring strut”.
Replacement:
Vehicle with spacer ring:
Note:
Spacer ring (A) is fitted in vehicles with ”rough road package” version.
Unscrew nuts.
Remove spacer ring (A) from support bearing.
Installation note:
Align spacer ring (A) using centering pin (1) to support bearing and place
in position.
If necessary, twist/drive out centring pin (1).Note:

If a support bearing (2) was fitted without centring pin (1), the centring
pin (1) of the new support bearing (2) must be driven or twisted out.
After installation:
If a support bearing is installed without a centring pin, perform a
wheel alignment.
31 33 095 Measuring ride-level height of vehicle

Move vehicle into normal position
Determine actual ride height (A) ‐ to do so, attach tape measure to rim
flange (2) at bottom middle and measure to lower edge of wheel arch (1).
31 33 100 Removing and installing/replacing coil spring for front left or front
right spring strut
Installation note:
must be replaced.
must be replaced.
Important!
Both coil springs on the relevant axle must be replaced only in the
event of corrosion breakage!
For all E70/E71/E72 vehicles: When replacing coil spring, always
renew spring pad at bottom
Note:
The coil spring is allocated in the Electronic Parts Catalogue (EPC) under
the "Spring table" menu item after the vehicle identification number has
been entered and the optional equipment of the particular vehicle has
been selected.
Note:
Procedure is described in the document ”Replacing front left or right
spring strut”.
After installation:
Check headlight adjustment, correct if necessary.
31 35 000 Removing and installing/replacing front stabilizer

Remove stabilizer link on both sides from stabilizer
Unscrew nuts.
Remove stabilizer from engine carrier.
Installation:
Check rubber mount on both sides, replace if necessary.
Replacement:
Remove rubber mount on both sides from stabilizer.
31 35 005 Removing and installing/replacing push rod (anti-roll bar link) for
left/right anti-roll bar
Release nut; if necessary, grip with open-end spanner.

Remove anti-roll bar link (1) from anti-roll bar (2).
Installation note:
Release nut; if necessary, grip with open-end spanner.

Remove anti-roll bar link from spring strut.
Installation note:
Important!
Never tighten the anti-roll bar link with an impact wrench!
Do not twist the joint of the anti-roll bar link when tightening the nut!
Twisting the joint must never be used to counter the screw
connection!
The plastic strapping (1) may not be broken as marked in area (2) with
arrows.
If the plastic strapping is broken, the anti-roll bar link must be replaced.
31 35 040 Replacing rubber mount for stabilizer on body on left or right

Remove stabilizer from front axle carrier
Remove retaining bracket (1) and rubber mount (2) on both

sides.Installation:
Keep retaining bracket (1), rubber mount (2) and stabilizer clean and free
from oil and grease.
31 60 ... Notes on removing and installing Low Profile band clamps

31 5 200
2 413 949
Important!
During removal Low Profile band clamp (dotted line) is
overstretched and must not be reused!
Depending on the design of the Low Profile band clamps, a different

special tool (pliers) is needed for installation.
Identify band clamp and find required special tool.
Band clamp type A = pliers 31 5 200
Band clamp type B = pliers 2 413 949
Installation (type A):

Position Low Profile band clamp in installation position (A) on gaiter.
Place special tool 31 5 200 on tabs (1, 2).
Note:
Make sure that the movable leg (3) of the special tool is placed on
tab (1).
Check and if necessary correct positions of gaiter and Low Profile band
clamp.
Compress Low Profile band clamp with special tool 31 5 200 and press on
end of band clamp (1).
Relieve tension on special tool and remove.
Check hook fastener (H); if necessary, repeat operation with new
Low Profile band clamp.
Installation (type B):

Position Low Profile band clamp in installation position on gaiter.
Place special tool 2 413 949 on tabs (1).
Check and if necessary correct positions of gaiter and Low Profile band
clamp.
Press Low Profile band clamp together with the special tool 2 413 949
until the hook fastener engages.
Relieve tension on special tool and remove.
Check hook fastener; if necessary, repeat operation with new
Low Profile band clamp.
31 ... . Front axle overview
0 Safety precautions and general

information
1 Thrust bearing 8 Power steering gear

2 Coil spring 9 Stabilizer/stabilizer suspension
3 Spring strut shock absorber 10 Front axle support
4 Control arm 11 Steering knuckle/wheel bearing
4.1 Bracket/rubber mount for control arm 12 Stabilizer link
5 Brake disk Testing/adjustment work
6 Brake caliper Troubleshooting (front axle/shock absorber)
7 Tie rod

7 Centering pin
8 Grease cap
9 Nut

temperature.
Installation note:
curing)
32 00 620 Adjusting rear axle

32 3 030
E46 only: Important!

Eccentric bolts must be replaced prior to camber adjustment!
Note:
A camber change always means a toe change as well. The camber must
therefore be adjusted first.
Adjusting camber:
Replace eccentric bolt , compress/deflect car and perform chassis/wheel
alignment check again.
Replace nut (2) and tighten down to 5 Nm.
Turn eccentric bolt (1) to adjust camber to setpoint value.
Tighten nut (2).
Tightening torque 33 32 11AZ .
Adjusting toe:
Slacken bolts of bearing support by approx. 1 to 1.5 turns.
Attach special tool 32 3 030 to bolt head and pin (1).
Turn special tool 32 3 030 to adjust toe to nominal value.
Tighten down screws.
32 00 610 Adjusting toe-in and camber on front axle

32 3 140
Important!
Changes in axle geometry caused by accidents must under no
circumstances be rectified by camber adjustment!
Note:
Camber and toe-in influence each other. Adjust the toe-in first in order to
simplify the adjustment procedure.
The centering pin may only be driven or twisted out if the camber is
outside the specified tolerance after toe adjustment.
Adjust toe-in:
Move steering into straight-ahead position by means of markings on
cap (1) and steering gear (2).
Align steering wheel and secure with steering wheel arrester.
Clean thread on tie rod.

Slacken clamping nut (1), gripping tie rod end in the process.
Turn tie rod (2) to adjust toe-in to specified value.
Tighten down clamping nut (1).
If necessary, correct installation position of gaiter.
Adjusting camber:
Remove protective cap.
Twist/drive out centering pin (1).
Clean wheel arch from below in area of support bearing with compressed
air.
Slacken nut (2).
Slacken nuts (3) approx. 1 to 1.5 turns.
Insert special tool 32 3 140 in opening of wheel arch and over nuts.
Turn nut in special tool 32 3 140 to adjust camber to specified value.
Replace nut (2) and tighten down.

Replace nuts (3) and tighten down.

After installation:
Check directional stability of car; if necessary, repeat toe-in
adjustment
32 00 150 Carry out Kinematics Diagnosis System wheel alignment with
vehicle load up to design position
Attention!
Carry out wheel alignment with DIN load only:
If the technical prerequisites for alignment with ride height input
are not fulfilled
If the vehicle in question is a damaged vehicle
Note:
Read and comply with General information and definitions.
Read and comply with General chassis definition.
Update KDS data states
Check compliance with test conditions, repair vehicle if necessary.
If necessary, prepare vehicle hoist.

Drive vehicle onto vehicle hoist.
Note: The front and rear wheels must be positioned centrally on the
rotary and sliding plates.
NOTE: Rotary plates may vary from illustration depending on the
manufacturer!
Note:
Vehicles with active steering:
Start up active steering prior to wheel alignment!
Attach pickup/ride height marks to vehicle (observe specifications

from the various equipment manufacturers).
Enter customer and vehicle data
Identify chassis version and select vehicle
Enter tyre inflation pressure and tread depth
Move vehicle into design position
Install brake pedal tensioner
E81, E82, E84, E87, E88, E90, E91, E92, E93: Attention!
Risk of damage!
In order to avoid damaging the front side panel during the
”Max. steering angle” drive-in routine, make sure the pickups are
removed from the quick-clamping holders/quick-clamping units
during output and input alignment. In the process do not detach the
connecting cable from the pickups or the rotary plates.
Note:
After the drive-in routine, reconnect the pickups to the quick-clamping
holders/quick-clamping units, align using the bubble levels and secure in
place.
Remove locking pins from both rotary and sliding plates.

Perform input measurement in accordance with equipment
manufacturer's instructions.
If necessary, adjust front axle and rear axle
Perform output measurement in accordance with equipment
Save and print out test record.
Insert locking pins into both rotary and sliding plates
Remove chassis/wheel alignment system
If necessary, carry out alignment of ACC sensor
Attention!
Only on vehicles with Active Cruise Control:
Because the driving axis is the reference for ACC alignment, it is
necessary after an alignment of the rear axle, which alters the
driving axis, to check the alignment of the ACC sensor as well!
It is not necessary to check the ACC sensor after only one
adjustment of the front axle!
Only in event of customer complaint (e.g. poor driving performance):
Attention!
Do not remove screws/bolts (front axle support to engine
support or body)!
Slacken all screws/bolts (front axle support to engine support or body)

and then retighten to specified torque.
Refer to Lowering front axle support.
61 31 996 Carrying out steering angle sensor adjustment
Important!
In vehicles with active steering, steering angle sensor adjustment is
integrated in the service function ”Initial operation/adjustment for
active steering” and must not be carried out separately!
Note:
Steering angle sensor adjustment must be carried out:
Before adjustment work on the front axle/steering
after all mechanical work on the steering system
E36 Z3, E38: If Dynamic Stability Control (DSC) is installed
E46 (All-wheel drive vehicle), E53, E83: After the battery has been
disconnected
After the following components have been
replaced/encoded/programmed:
Fixture for switches of steering column / switch cluster /
steering angle sensor
Dynamic Stability Control (DSC) control unit
Control unit active anti-roll stabilization (ARS)
Connect the vehicle to the diagnosis system or Software Service

Station.
Select and carry out steering angle sensor adjustment under Service
functions.
Headaches
Dizziness
Stomach aches
Vomiting
Diarrhoea
Cramps/fits
Unconsciousness

or mugs)
First aid measures:

immediately.
31 00 ... Front axle + steering: wheel/chassis alignment check must be
carried out after the following work
Steering gear to front axle carrier
Support bearing to body (if centering pin is missing)
Tie rod end to tie rod

1. Front axle carrier
2. Steering gear
3. Control arm
4. Support bearing (if centering pin is missing)
5. Steering knuckle
6. Tie rod end
7. Tie rod
32 00 ... General chassis and suspension definitions
1. Toe 5. Wheel misalignment

2. Camber 6. Camber
3. Caster (with 10° or 20° wheel lock) 7. Rear-wheel position
4. Toe angle difference (with 20° wheel lock) 8. Toe
9. Geometrical driving axis
32 00 ... General information and definitions
Toe angle difference

a Toe difference angle
D Centre point of operating circle
The toe angle difference is the angle adjustment of the inner cornering
wheel relative to the outer cornering wheel when negotiating a curve.
Steering is designed in such a way that angular position of wheels
changes as steering lock progresses.
A correctly adjusted toe angle difference produces equal values for left
and right lock with consideration of factory tolerances.
Toe angle difference provides information on corresponding operation of
steering trapezoid for left or right steering lock from centre position.
Camber
Inclination of the wheel from the perpendicular.
Toe
Reduction in distance of front of front wheels to rear of front wheels. The
toe-in prevents the wheels from moving apart during driving and thus:
the wheels from vibrating and grinding
excessive tire wear
excessive strain on the steering linkage and its links/joints
heavy vehicle steering
Measurement is performed in ”straight-ahead mode”.
Castor
Is the inclination of the kingpin in the direction of travel viewed from the
side. The line through the centre point of the spring strut support bearing
and the control arm ball joint corresponds to the ”kingpin”.
Thanks to caster, wheels are pulled and not pushed. In a similar manner
to king pin inclination, when driving in curves or around corners, returning
forces are reproduced to help return wheels to straight-ahead position.
Geometrical driving axis 1
Is the angle bisector from the total rear-wheel toe.
Front-wheel measurements are taken in reference to this axis.
Symmetrical axis 2
Centre line running through front and rear axles.
Wheel misalignment
Angle by which one front wheel is displaced more towards front or rear
than the other front wheel. The wheel offset angle is positive when the
right wheel is displaced towards the front and negative when it is
displaced towards the rear.
Kingpin offset/scrub radius

Is the distance from the centre of the wheel contact face to the
intersection point of the kingpin extension. The line through the centre
point of the spring strut support bearing and the control arm ball joint
corresponds to the ”kingpin”.
The scrub radius is influenced by camber, kingpin angle and wheel offset
of the wheel rim.
32 00 ... Identification of suspension without label
Note:
If the frontÂ spring strut does not have a label for suspension
identification, the type of suspension can be identified from the part
number in the Electronic Parts Catalogue.
32 00 ... Identification on volume production suspension, sports suspension
etc.
Suspension design can be identified by label (K) on front spring strut.
Label (K)
1 = BMW number
2 = Suspension design:
4Z Serie = 4-cylinder Series
6Z Serie = 6-cylinder Series
4Z Sport = 4-cylinder sports suspension, low-slung
6Z Sport = 6-cylinder sports suspension, low-slung
M3/2 = M3 Coupé
M3/C = M3 Convertible
3 = Side designation:
L = left / R = right
”Rough road package” suspension can be identified by spacer ring (A) of

support bearing.
32 00 ... KDS data statuses
Nominal values for wheel alignment are not published in ISTA.
The current setpoint values are made available in the workshop equipment portal.
See:
www.bmwbroup-wep.com
Workshop Equipment catalogue:
Select Wheel alignment
Select KDS nominal values
E.g. Select Beissbarth KDS update, Copy data
Or:
Aftersales Assistance Portal (ASAP)
Profile: Select Service/Technology
Select Workshop equipment
Select Start BMW
Select Workshop equipment catalogue
Select Wheel alignment
Select KDS nominal values
E.g. Select Beissbarth KDS update, Copy data
We recommend that the data records are updated on a regular basis.
Please contact your subsidiary if you do not have access to the portals listed.
32 00 155 Kinematics Diagnosis System wheel alignment with ride height
measurement without loading the vehicle
Attention!
Do not perform wheel alignment without loading the vehicle:
If the technical prerequisites for alignment with ride height input
are not fulfilled
If the vehicle in question is a damaged vehicle
Note:
Read and comply with General information and definitions.
Read and comply with General chassis definition.
Update KDS data states
Check compliance with test conditions, repair vehicle if necessary.
If necessary, prepare vehicle hoist.

Drive vehicle onto vehicle hoist.
Note: The front and rear wheels must be positioned centrally on the
rotary and sliding plates.
Note: Rotary plates may vary from illustration depending on the
manufacturer!
Note:
Vehicles with active steering:
Start up active steering prior to wheel alignment!
On vehicles with rear axle slip angle control:
The service function "Moving HSR actuator to the centre position" is
included in the active steering start-up.
Attach pickup/ride-height marks to vehicle (observe regulation of

the different device manufacturers).
If necessary, switch on chassis alignment system.
Enter customer and vehicle data
Identify chassis version and select vehicle
Enter tyre inflation pressure and tread depth
Measure vehicle ride height with tape measure (only Beissbarth
KDS II wheel alignment equipment)
If the ride height is outside the tolerance range (+40/-20 mm), load
or unload vehicle accordingly to adjust the vehicle in this ride-height
window
Install brake pedal tensioner
E81, E82, E87, E88, E90, E91, E92, E93: Attention!

Risk of damage!
In order to avoid damaging the front side panel during the
”Max. steering angle” drive-in routine, make sure the pickups are
removed from the quick-clamping holders/quick-clamping units
during output and input alignment. In the process do not detach the
connecting cable from the pickups or the rotary plates.
Note:
After the drive-in routine, reconnect the pickups to the quick-clamping
holders/quick-clamping units, align using the bubble levels and secure in
place.
Remove locking pins from both rotary and sliding plates.

Perform input measurement in accordance with equipment
If necessary, adjust front axle and rear axle
Perform output measurement in accordance with equipment
Save and print out test record.
Insert locking pins into both rotary and sliding plates
Remove chassis/wheel alignment system
If necessary, carry out alignment of ACC sensor
Only in event of customer complaint (e.g. poor driving performance):

Attention!
Do not remove screws/bolts (front axle support to engine
support or body)!
Slacken all screws/bolts (front axle support to engine support or body)

and then retighten to specified torque.
Refer to Lowering front axle support.
Attention!
For vehicles with ACC:
As the driving axis is the reference for ACC alignment, it is
necessary to also check the alignment of the ACC sensor after a
setting of the rear axle, which alters the driving axis.
It is not necessary to check the ACC sensor after only one
adjustment of the front axle!
32 00 ... Moving vehicle into design position

Version with air spring system:

Remove ignition key
If necessary, pull fuse for air supply system control unit
Add/distribute weights in area of spring struts until the vehicle ride
height is within the tolerance (refer to TechnicalÂ Data).
Measure vehicle ride height
32 00 ... Moving vehicle into normal position

Check compliance with test conditions, repair vehicle if
necessary.
Version with air spring system: Carry out ride height adjustment
Check vehicle interior and luggage compartment (incl. spare wheel
well) for load, unload vehicle if necessary
Introduce DIN load (refer to Technical Data) into vehicle
Determine vehicle ride height
Note: If the vehicle ride height is not inside the tolerance (refer to
technicalÂ data), the vehicle must be repaired.
32 00 ... Notes and specifications for the replacement of the steering
gear, steering column and the steering shaft following accident damage
Situation:
In the event of accidents or driving conditions similar to accidents, shock-like loads can cause different types
of damage to steering boxes. When a steering box is externally undamaged, it is sometimes only possible to
identify damage with great difficulty and with great effort. However, damage of this nature poses an
unacceptable risk to the vehicle because it can result in failure of the steering system.
Because of the disproportionate amount of effort involved, it is generally not sensible to check thoroughly all
the individual components of the steering box and as an alternative it is necessary to take into account other
components which can be checked more easily.
Procedure:
The steering box must be replaced if one or more of the following points apply:
A. Visible or noticeable damage to the steering box
Version with electric steering box (EPS): Examine in particular the control unit with all plug
connections for damage and hairline cracks.
B. Unacceptable torque increase and jamming when the steering box is turned from lock to lock (without
hydraulic/electrical assistance)
C. Fire damage
D. Damage, permanent deformation or fractures to:
Wheel rims in the event of a negative result from the wheel alignment check
Spring struts, steering stubs, wheel carriers
Wishbones
Body-side attachment points for wheel guide/control components
Front axle support
Pitman arms
Track rods
Steering column
A lopsided steering wheel, significant deviations of camber/track values and noises when cranking
the steering can be additional indications for the damage/deformations listed here.
This guideline is binding for all accident repairs to BMW and MINI vehicles.
Note:
If the steering box replacement work which is required for safety reasons is refused by the customer
or an insurance company for cost reasons, a memorandum to that effect must be drawn up and
countersigned by the party bearing the costs of the accident repair.
For a corresponding example of the memorandum, see Service Information (bulletin) 320188(828)
Appendix 1.
Actual situation of the steering column and steering shaft:

of damage to the steering shaft and steering column. In case no external damaged of the steering column and
the steering shaft can be noticed, it is sometimes only possible to identify damage with great difficulty and with
great effort.
Proceedure for steering column and steering shaft:
The steering column and steering shaft must be replaced if one or more of the following points apply:
Visible or noticeable damage, deformation or breakage of the steering column or steering shaft
Damage, permanent deformation or breakage of the track rod
Unacceptable torque increase and jamming when the steering column is cranked from limit position to limit
position (without hydraulic/electrical assistance)
If the wheel alignment nominal data cannot be reached after all the damaged wheel components are
changed (exceedance of the permissible wheel alignment tolerances). If required, attach the
measurement protocol of the invoice/certificate
Positive check for activated crash system of the steering column:
If no damage is visible on the steering column, the mechanical steering column must be checked for an
activated crash system:
1. Open ELV
2. Pull steering wheel out towards the driver (towards the body) until the physical limit position is
reached, but do not use excessive force
3. Push steering wheel towards engine compartment (approx. 20-30 mm away from body) into the
comfort position and lock
If no end stop is present when pulling out the steering column or the gaiter of the steering column
shroud has tension, the crash system has activated and the steering column is to be renewed.
Note:
If the steering column/steering shaft replacement work which is required for safety reasons is rejected
by the customer or an insurance company for cost reasons, a memorandum to that effect must be
drawn up and countersigned by the party bearing the costs of the accident repair.
For corresponding specimen of the memorandum, refer to Service Information 320188(828) Appendix
1
Attention!
The vehicle's operating licence will be invalidated whenever the function of any of its safety
components is compromised!
32 ... . Overview of steering
Safety precautions and general

information
1 Tie rod end / tie rod / gaiter 8 Steering column

2 Cooling coil 9 Overview of steering wheel/casing components
3 Power steering gear 10 Steering angle sensor
4 Auxiliary steering pump 11 Sleeve for steering spindle
5 Fluid reservoir 12 Steering spindle lower section
6 Flexible disk/double joint/universal joint 13 Adjustment work
7 Interlock cable 14 Troubleshooting
32 .. .. Overview of steering wheel / casing components / lock cylinder
1 Steering wheel 4 Lock cylinder

2 Airbag unit 5 Lower steering column casing
3 Upper steering column casing 6 Control lever
32 00 ... Performing rim runout compensation
Note:
Rim runout compensation involves electronically recording the lateral
runout of the rim and the possible clamping error of the quick-clamping
unit for one wheel rotation and compensating the toe and camber for
measurement/alignment.
Raise body.
Perform rim runout compensation in accordance with equipment
Compress/deflect car.
33 00 ... Rear axle: wheel/chassis alignment check must be carried out after
the following work
Rear axle carrier to body
Bearing block to trailing arm / body
Upper control arm to rear axle carrier / trailing arm
Lower control arm to rear axle carrier / trailing arm

1. Rear axle carrier / rubber mount
2. Lower control arm / rubber mount
3. Trailing arm / rubber mount / bearing block / ball joint
4. Upper control arm / rubber mount / ball joint
Danger of injury!
Impaired sight

First aid measures:

Warning!
Recycling:

ground.
32 00 ... Test conditions for chassis/wheel alignment check
Observe the following test conditions prior to the chassis/wheel alignment check:
1. Only BMW approved wheel and tyre combinations are installed on the vehicle.
2. Correct tread depth. The tread depth for each axle may differ from left to right by max. 1‐2 mm.
3. Correct tyre pressure (see label on vehicle).
4. All chassis and suspension components must be technically OK.
5. Condition of suspension and shock absorbers OK: Visually inspect for breakage, etc.
6. Vehicles with self-levelling suspension: Pull fuse of air supply system so that there is no controlling down
or up.
Situation:
Procedure:
C. Fire damage
Wishbones
Front axle support
Pitman arms
Track rods
Steering column
Note:
Appendix 1.

great effort.
1. Open ELV
Note:
1
Attention!
32 11 ... Notes on checking steering backlash on vehicles with rack-and-
pinion steering (with front axle raised)
Note:
When the front axle is raised, the applied force is distributed via the tie
rod into horizontal and vertical forces. If there is now no electric or
hydraulic assistance, the forces created cause the thrust member (1) to
be unloaded against the spring (2). The play created in this way is
incorrectly referred to as steering backlash.
3 = Rack
Important!
Target status: steering must be free from play in all the mechanical
components (except for steering gear and tie rod)!
Note:
For checking purposes, the steering gear must be pressurised by means
of electric or hydraulic assistance.
Hydraulic steering assistance: Start engine

Electro-hydraulic steering assistance: Switch ignition on
Electric steering assistance: Turn on ignition and start engine
32 11 100 Replacing gaiter for steering gear on left or right
Important!
The power steering gear must be replaced if the polished surface of
the rack is damaged (e.g. by corrosion)!
After installation:

Release both ear clips and pull gaiter off steering gear.
Important!
To avoid damage to rack and to suspension mounting, move rack in
as far as possible.
Screw tie rod off rack of steering gear (34 WAF).

If necessary, cut open gaiter and remove.
Clean tie rod and apply grease to taper.

Note:
This ensures that the gaiter is not rotated when the tie rod is rotated.
Fit new gaiter over tie rod.

Fit support ring (1) from repair kit.
Screw tie rod onto rack of steering gear.
Fit gaiter with new ear clips.
32 13 006 Bleeding power steering unit
Warning!
Important!
Adhere to the utmost cleanliness. Do not allow any dirt to enter the
hydraulic system.
Using contaminated equipment to add fluid may introduce dirt
particles into the fluid reservoir and significantly reduce the service
life of the power steering system. Do not use any filler funnels or
similar!
The fill level may only be checked or adjusted when the engine is
stopped! The fluid temperature should be approx. 20 °C here.
Ensure that the cap is fully screwed in prior to the fill level check.
Note:
To avoid mix-ups when filling with hydraulic fluid, mark the fluid reservoirs
or their caps with identification marks.
ATF Automatic transmission fluid

CHF Pentosin CHF11S
1. Thoroughly clean fluid reservoir and its immediate surroundings

2. Check and correct fill level
Note: The fill level can come to rest above the ”MAX” mark when
the engine is at normal operating temperature. This is dictated by
the design in that the marking on the dipstick is referred to a fluid
temperature of 20 °C. With the engine at normal operating
temperature (approx. 50-60 °C fluid temperature) adjust a fill height
10 mm above the ”MAX” mark. Do not under any circumstances
draw off the fluid to the ”MAX” mark when the engine is at normal
operating temperature.
Hydraulic fluid: BMW Service Operating Fluids
3. Start engine
4. Turn steering wheel left and right twice in each case up to full lock; if
necessary, top up hydraulic fluid (e.g. if hydraulic system is
completely drained)
5. Move steering wheel to straight-ahead position and turn off engine
6. Check and correct fill level with engine stopped
7. Check hydraulic system for leaks
Situation:
Procedure:
C. Fire damage
Wishbones
Front axle support
Pitman arms
Track rods
Steering column
Note:
Appendix 1.

great effort.
1. Open ELV
Note:
1
Attention!
32 13 060 Removing and installing/replacing power steering gear
Important!
hydraulic system.
Seal off pipe connections with plugs.

Draw off and dispose off hydraulic fluid from fluid reservoir
Remove tie rod end on both sides from swivel bearing
Replacement only:
Remove tie rod end at both ends of tie rod
Remove flexible disk/universal joint from power steering gear
Release banjo bolts.

Disconnect hydraulic lines from power steering gear.
Installation:
Make sure hydraulic lines are laid without tension and with sufficient
spacing to adjoining components.
Unfasten screws.
Remove power steering gear towards front.
Installation:
Replace screws and self-locking nuts.
After installation:
Fill and bleed hydraulic system
Check pipe connections for leaks
32 41 ... Instructions for removing and installing ear clips

32 1 260
Note:
The work steps are show on assorted components.
Ear clip must always be replaced.
To remove an ear clip, place special tool 32 1 260 at right angles to ear
and cut ear open.
The ear clip can be fitted not only axially but also radially after the hook
fastener has been opened.
Attach hook fastener and press ear together with special tool 32 1 260 .
The diagonal cutting pliers of special tool 32 1 260 can be used in areas
which are difficult to access.
Important!
Gap (A) max. 1 mm!
32 21 151 Replacing left or right tie rod

32 3 090

Remove front wheel
After installation:
Unfasten nut.
Force tie rod end off swivel bearing with special tool 32 3 090 .
Installation:
Keep journal on tie rod end and bore hole in swivel bearing clean and
free from grease.
Determine measurement (A) to simplify following adjustment of front axle.

Release clamping nut.
Screw off tie rod end; if necessary, grip tie rod with open-end wrench.
Installation:
Check gaiter, replace if necessary.
Mount clamping ring (1).
Screw in tie-rod end to distance (A).
32 21 231 Replacing left or right tie rod

Remove tie rod end from swivel bearing
Remove gaiter from power steering gear and slide back
After installation:
Important!
To avoid damage to rack and to suspension mounting, move rack in
as far as possible.
Screw tie rod off rack of power steering gear (WAF 34).
Determine measurement (A) to simplify following adjustment of front axle.

Release clamping nut.
Screw off tie rod end; if necessary, grip tie rod with open-end wrench.
Installation:
Use a new gaiter.
Mount clamping ring (1).
Screw in tie rod end to measurement (A).
32 31 ... Disassembling and assembling steering column

32 3 040
32 3 110
61 3 100

Remove steering column
After installation:
Unfasten screws.
Remove cable duct.
Installation:
New screw: black
Old screw: silver
Slide special tool 61 3 100 between housing and ring antenna and force
off ring antenna.
Installation:
Fit rubber ring.
Turn lock barrel to position ”R” (first click).
Note:
In order to be able to turn the lock cylinder in cars with interlocks, it is
necessary to press the lock inwards through the hole (1).
Press special tool 32 3 110 into hole and withdraw lock cylinder.
Note:
Lock (1) is unlocked with special tool 32 3 110 and the lock cylinder can
now be removed. If necessary, turn special tool in hole.
Unhook helical coiled spring at both ends.
Remove bushing (1).

Press crash disk (3) off crash sleeve (2).
Lift crash sleeve (2) out of groove of steering shaft and remove.
Remove crash disk (3).
Installation:
Replace bushing (1) and crash sleeve (2).
Unfasten nut.
Withdraw operating lever.
Installation:
1. Washer
2. Axial needle bearing, grease needles if necessary.
3. Always replace self-locking nut.
Fit disk (1), needle bearing (2) and new nut (3).
Move adjusting lever into locked position.
Screw on nut (3) until contact is made with needle bearing (2).
Open and close adjusting lever.
Tighten nut (3) to torque value 1.
Open and close adjusting lever again.
Open and close adjusting lever again.
Tighten nut (3) again to torque value 2.
Observe tightening torque without fail; the actuating force of the

operating lever is adjusted by means of the tightening torque.
Installation:
Press clamping disk (1) onto operating lever. Marking (K) must point to
operating lever.
Ensure needle rollers are in correct position.
Mount operating lever with clamping disk (1) - hold pressed together - on
housing.
Square section of clamping disk (1) must snap into elongated hole of
mounting bracket.
Installation:
1. Spring
2. Needle roller
Grease contact area (A) (Glissando, refer to BMW Parts Service) and
position needle rollers (2) vertically in operating lever.
Installation:
Fit washer (1) on clamping disk (2).
In this case, wide tongue (1.1) must be aligned to wide link (2.2).
K = Marking for installation direction
Remove cable holder.
Unscrew nut (1).

Remove screw (3) with washer (2).
Installation:
Screw (3) must fit in both guide Guide bushes. Install nut with Loctite.
Tightening torque: 32 31 8AZ
Remove mounting plate (1) and mounting bracket (2).Installation:
Insert mounting bracket (2) into guide of mounting plate (1).
Installation:
Replace sliding blocks (1) and stop buffer (2) if necessary.
Installation:
Replace stop element (1) and friction plate (2) if necessary.
Do not grease friction plate (2).
Installation:
If necessary, replace and grease guide bushings (Glissando, refer to
BMW Parts Service).
Press down both locking hooks.
Detach steering angle sensor.
Installation:
Locking element (1) must engage in steering angle sensor!
Both locking hooks (2) must be snapped into place.
Installation:
Push in steering spindle upper section until stop.
Locate special tool 32 3 040 with steering angle sensor. Both lugs (1) of
special tool must engage in openings of bearing (2).
Push on steering angle sensor.
Installation:
Slide special tool 32 3 040 into steering angle sensor. The link must rest
in an opening in the steering angle sensor.
Press down locking hooks.
Remove locking element.
Unfasten screws.
Remove ignition starter switch.
Installation:
Secure screws with paint.
32 31 020 Removing and installing / replacing lower section of steering
column trim
Move steering column in ”top” and ”extended” position.
Knock through pin (1) on both expansion rivets (2) towards

interior.Installation:
Expansion rivets can be used again. Insert expansion rivet (2) and
push in pin (1) until flush.
Press both sides of marked area of upper section of steering column trim
inwards and pull lower section downwards to remove.
32 31 070 Removing and installing / replacing lower section of steering
spindle
After installation:
Turn steering wheel in both directions to full lock
Note: The airbag warning lamp must not light up in the process.
Check directional stability of car
Move steering wheel to straight-ahead position.

Lock steering lock -> remove ignition key.
Release clamping screw.
Detach flexible disk/double joint from power steering gear.
Installation:
If necessary, move power steering gear to straight-ahead position -
markings on cap (1) and housing (2) must match up.
Replace clamping screw.
Release clamping screw.

Remove lower section of steering spindle with flexible disk/double joint.
Installation:
Lower section of steering spindle can only be attached in one position to
the steering column.
Replace clamping screw.
32 31 090 Removing and installing steering column

Remove steering wheel
Remove steering column trims
Remove trim panel for pedal assembly
Remove lower section of steering spindle
After installation:
I. Check for ease of movement in overall adjustment range of
steering column to adjoining components/wires
II. Turn steering wheel in both directions to full lock. The airbag
warning lamp must not light up in the process.
Unfasten screws.
Disconnect all plugs and remove switch block.
Disconnect plug from ring antenna.
Push steering spindle upper section into steering column.
If necessary, remove cable for Interlock.Installation:

Unlock connector and remove.
Detach wiring harness from cable duct.
Release shear screw (1) (e.g. mill off or drill out).

Release screw (2).
Installation:
Tighten down new shear screw until screw head shears off.
Important!
New feature of model series: shear screw (1) is omitted and can
thus be replaced by a normal M8 screw!
Unfasten screws.
Remove steering column.
32 31 082 Removing and installing/replacing steering angle sensor

32 3 040

After installation:
Replacement only: Carry out programming/coding
Note:
For purposes of clarity, the following work steps are shown on a steering
column which has been removed.

Lift crash sleeve (2) out of groove of steering spindle upper section.
Remove crash disk (3), crash sleeve (2) and bushing (1).
Installation:
Replace bushing (1) and crash sleeve (2).
Unscrew nut (1).

Remove screw (3) with washer (2).
Installation:
Screw must fit in both guide bushes.
Coat nut (1) with Loctite and tighten down.
Installation:
Observe guide bushes.
Pull down steering column.

Press down both locking hooks.
Detach steering angle sensor.
Press down locking hooks.

Remove locking element.
Slide special tool 32 3 040 into steering angle sensor. The link must rest
in an opening in the steering angle sensor.
Push in steering spindle upper section up to stop.
Locate special tool 32 3 040 with steering angle sensor. Both lugs (1) of
special tool must engage in openings of bearing (2).
Push on steering angle sensor.
Important!
Locking element (1) must be inserted in holder of steering angle
sensor.
Both locking hooks (2) must be snapped into place.
32 31 241 Replacing adjusting lever for steering column

Remove lower section of trim

Remove wiring harness (2) from cable guide (3).
Release screws (1), remove cable guide (2).
Important!
Clamping bearing must be held down until secured.
Securing clamping bearing:

Pull retaining tab (1) in direction of steering column.
Turn clamping bearing head (3) so that pin (2) on clamping bearing is
held by retaining tab (1).
Important!
The secure fitting must not be released when the adjusting lever (3)
is removed.
Slacken nut (1).

Remove needle bearing (2) and washer.
Pull out adjusting lever (3).
Installation:
Replace nut (1).
Move adjusting lever (3) into locked position.
Fit washer and needle bearing (2) and screw on nut (1) until it
contacts needle bearing (2).
Open and close adjusting lever (3).
Open and close adjusting lever (3) again.
Open and close adjusting lever (3) again.
Tighten nut (1) again to torque value 2.
Important!
Observe tightening torques without fail!
The clamping force is adjusted by means of the tightening torque.
32 31 053 Replacing flexible disc

Move steering wheel to straight-ahead position
Remove ignition key.
If necessary, remove assembly underside protection
After installation:
Release both clamping screws from flexible disc.

Detach flexible disc from power steering gear.
Detach flexible disc from lower section of steering spindle and remove.
Installation:
If necessary, move power steering gear to straight-ahead position -
markings on cap (1) and housing (2) must match up.
Replace clamping screws.
32 31 091 Replacing steering column
Remove steering column.

Modify lock cylinder.
Modify steering angle sensor.
After installation:
I. Check for ease of movement in overall adjustment range of
steering column to adjoining components/wires
II. Turn steering wheel in both directions to full lock. The airbag
warning lamp must not light up in the process.
32 31 102 Replacing steering spindle sleeve

Remove trim panel for pedal assembly.
After installation:

Lift crash sleeve (1) out of groove of steering column and pull down.
Installation:
Replace crash sleeve (1).
Remove holder for accelerator pedal.Installation:

Tightening torque = 2.8 Nm.
Remove sleeve from bulkhead.Installation:
Make sure sleeve is correctly seated - opening in bulkhead.
32 31 003 Replacing upper section of steering column trim
Move steering column in ”bottom” and ”extended” position.
Unscrew screw.Installation:
Fit new expanding nut.
Press both sides of marked area on top section inwards and remove by
pulling upwards.
Unclip cover from top section.

Remove top section.
32 31 061 Replacing upper section of steering spindle
This procedure is described in the document ”Replacing steering column”.

32 32 170 Removing and installing/replacing interlock cable
Remove interlock cable from selector lever (version with interlock),

refer to MG 25.
Remove lower section of steering column trim,
refer to 32 31 020.
Open lock (1) and remove cable.Installation:

32 32 050 Removing and installing/replacing steering lock cylinder

32 3 110

Remove ring antenna
If necessary, unlock interlock cable through bore (1).

Turn ignition key to ”R” position.
Insert special tool 32 3 110 into release opening (arrow) and remove lock
cylinder.
Note:
Lock (1) is unlocked with special tool 32 3 110 and the lock cylinder can
now be removed. If necessary, turn special tool in hole.
32 33 000 Removing and installing/replacing steering wheel

Remove airbag unit
Move steering wheel/wheels to straight-ahead position
Release screw.
Unfasten plug connection.
Remove steering wheel.
Installation:
Move wheels to straight-ahead position.
Align steering wheel using marking to steering column and attach. The
retaining pins must also appear in the openings in the steering wheel.
Replacement only:
Remove cover with multifunction unit switch.
32 33 ... Replacing lower cover for sport steering wheel
Important!
Wood covers do not fit on sport steering wheels with plastic covers
and vice versa!
Note:
Procedure is described in the document ”Replacing switch on sport
steering wheel”.
32 34 ... Notes on scrapping BMW vehicles with gas generators
(airbag system)
62 1 210
62 1 233
62 1 270
62 1 280
62 1 310
62 1 320
62 1 330
The gas generator is a pyrotechnical component of:

Airbag module
Driver's/passenger airbag
Side airbags
Head airbag
Belt tensioner
Belt buckle tensioner
Safety battery terminal
Series 3: E30, E36, Z3, E46
Series 5: E28, E34, E39
Series 6: E24
Series 7: E23, E32, E38
Series 8: E31
Z8: E52
X5: E53
Gas generators that have not fired constitute a hazard (also to the environment)!
In accordance with accident prevention regulations and specific national regulations, gas generators must be
rendered unusable before they are scrapped. This is necessary because pyrotechnical objects can cause
injury if improperly activated (e.g. scrapping with flame cutters).
With above-mentioned vehicles which are scheduled for scrapping, it is always essential prior to draining and
further stripping work to ensure that all the gas generators in the vehicle are fired. The fired gas generators
can then be scrapped together with the vehicle.
Firing failure
If correct firing is not possible, the relevant components must (while observing the safety regulations for
handling airbag system components) be removed and disposed of by special disposal companies!
If a firing operation has failed:
Disconnect the firing device from the battery and
only approach the vehicle after a few minutes have elapsed
The components of an airbag system must always be disposed of. Such components must not be sold
on as used parts.
Firing
Firing of the gas generators may only be carried out by expert personnel and under the supervision of a
responsible person. Other standard accident prevention regulations (safety goggles, ear defenders etc.) must
also be observed.
The gas generators must be fired from the outside in the vehicle scheduled for scrapping with the doors
closed but with the tailgate, door windows and sunroof open. To fire the gas generators, use the BMW-
developed firing device with the corresponding cables.
Warning!
Once gas generators have been fired, observe a ventilation period of 10 minutes with the doors
opened. Only then is it permitted to continue work inside the vehicle.
Wear protective goggles and protective gloves when handling a fired gas generator!
The burning of solid fuel will heat up the airbag unit - danger of burns!
Wash skin with water after contact with fired gas generators!
1. Driver's airbag up to model year 94
1.1. Remove the lower section of the steering column paneling and separate the plug connection (orange)
from the airbag unit.
1.2 Connect the firing device 62 1 270 to the connector; if necessary, in conjunction with cable 62 1 280 or
62 1 233.
1.3 Maintain a distance to the vehicle in line with the ignition cable length (at least 10 m).
Always stand behind the vehicle (also applicable to other persons).
1.4 Connect the firing device to a 12 V battery.
1.5 Press switch on firing device - airbag fires. If no firing takes place, refer to Firing failure.
2. Driver's airbag with warning lamp integrated in steering wheel
2.1 Remove the airbag unit from the steering wheel. Comply with safety regulations for handling airbag
system components.
2.2. Pull connector off airbag unit. Cut off the cable with the detached connector at the outlet from the
steering wheel (cable length remaining on connector approx. 20 cm) and strip insulation at both cable
ends. Reconnect the connector to the airbag unit.
2.3 Re-install airbag unit, whereby both wire ends must lie outside the steering wheel. Caution! An airbag unit
that is not fastened in accordance with regulations can lead to injury when fired.
2.4 Connect cable 62 1 320 to cable ends and firing device 62 1 270.
2.7 Press switch on firing device - airbag fires. If no firing takes place, refer to Firing failure.
3. Belt tensioner E32, E34 up to model year 93
3.1 Insert the belt tongue into the belt buckle. If this is no longer possible, the belt tongue must be pushed
up to the hole in the B-pillar.
3.2 Mark the webbing with a chalk mark at the outlet of the B-pillar so that the belt tension can be checked
after firing has taken place.
3.3 Disconnect the plug connection to the belt tensioner at the airbag control unit. Installation location of the
airbag control unit: left side under the instrument panel.
3.4 Connect the firing device 62 1 270 to the connector using cable 62 1 280.
3.7 Press the switch of the firing device - belt tensioner fires.
If no firing takes place, refer to Firing failure.
4. Passenger airbag E32
4.1 Disconnect both plug connections to the passenger airbag on the airbag control unit.
Installation location of the airbag control unit: left side under the instrument panel.
4.2 Connect the firing device 62 1 270 to the connector using cable 62 1 280.
4.4. Connect the firing device to a 12 V battery.
4.5 Press switch on firing device - first airbag fires.
4.6 Connect the firing device to the second connector.
4.8 Press switch on firing device - second airbag fires.
5. Vehicles from model year 94 (all airbags, belt tensioner, safety battery terminal)
5.1 Remove connector from airbag control unit.

Installation location of the airbag control unit:
E36, E34 under rear seat
E31, E38, E39, Z3, E46, E53 under center console
Z8 under panel in area of handbrake lever
5.2 Connect firing device 62 1 270 in combination with cable 62 1 210 to 30-pin plug or with cable 62 1 310 or
62 1 330 (according to plug coding) to 50-pin plug.
5.5 Press firing device switch - gas generators fire.
5.6 If cable 62 1 310 / 62 1 330 (50-pin connector) has been used, only the gas generators on one vehicle
side are fired. If no firing takes place, refer to Firing failure.
5.7 Disconnect firing device from battery.
5.8 Connect firing device to free connector.
5.9 Maintain a distance to the vehicle in line with the ignition cable length (10 m distance to vehicle).
5.10 Connect the firing device to the battery.
5.11 Press firing device switch - gas generators on the other side of the vehicle fire.
(central airbag control unit, airbag system)
The gas generator is a pyrotechnic component of:
Airbag module
Side airbags
Head airbag
Knee airbag
Seat belt tensioner
Battery safety terminal
1 Series: E81, E82, E87, E88
3 Series: E46, E90, E91, E92, E93
5 Series: E60, E61 from build date 09/2005
X3:E83
X5: E53, E70
Z4: E85, E86
For vehicles mentioned above that are scheduled for scrapping, it is always essential prior to draining and
further disassembly work to ensure that all the gas generators in the vehicle are fired. The fired gas
generators can then be scrapped together with the vehicle.
Firing failure
If correct triggering is not possible, the relevant components must (while observing the safety regulations for
If a triggering operation has failed:
Disconnect the triggering device from the battery and
approach the vehicle only after a few minutes
on as used parts.
Ignition
Triggering of the gas generators may only be carried out by expert personnel and under the supervision of a
also be observed.
developed triggering device with the corresponding cables.
Warning!
The burning of solid fuel will heat up airbag unit - danger of burning hands!
1. Vehicles with central airbag control unit (all airbags, seat belt tensioners, battery safety terminal)
1.1 Expose airbag control unit.

1.2 Connect ”Airbagmaster”. For subsequent procedure, refer to SEDA operating instructions.
72 12 ... Procedure after airbag deployment as result of an accident
Replace all components that were affected by the accident and check all others!
Check and/or replace following components after airbag deployment:
Components
Sensor B-pillar (left/right)
Sensor front door (left/right)
Sensor seat, Driver-/passenger's side
Sensor, pedestrian protection
Front sensor (engine compartment)
Airbag control unit, vehicle interior
Procedure
Inspect visually for mechanical damage (housing, plug connections). Replace damaged
components.
Read fault memory
Disconnect the vehicle battery and adhere to the waiting period (at least 30 seconds)
Rectify faults
Reconnect the vehicle battery and adhere to the waiting period (at least 10 seconds)
Delete fault memory
Switch off ignition and wait at least 2 minutes (no consumers may be switched on during this period
such as interior light, radio, etc.)
Switch the ignition on (wait for at least 10 seconds)
Delete fault memory
If you cannot delete the fault memory: Replace the component that is causing the fault
Replace the airbag control unit in the following cases only:
In the case of visible external damage
In the case of a corresponding fault memory entry (airbag indicator light is illuminated)
Cables and connectors
Components and procedure
Check cables and connectors for damage, replace if necessary.
(e.Â g. corrosion, correct engagement, bent pin)
Seat belt system
Components
Automatic reel
Seat belt tensioner
Seat belt height adjustment
Anchor fitting tensioner
Seat belt buckle
Procedure
Check components, replace if necessary
Additional door lock: Check for foreign body, remove it if necessary.
Seats
Components
Seat
Airbag module
Active head restraint
Procedure
Check seats (functional check of seat mechanism), replace if necessary
Check seat connection
Replace gas generator of active head restraint
If the severity of the crash has not caused any other damage to the seat, only the triggered gas
generator needs to be replaced.
External feature: The triggered head restraint is folded forwards and engaged.
The repair work can be carried out in the vehicle with the rear panel removed. The entire system can
be pushed back into its original position and the new gas generator installed.
The gas generator can be replaced up to 5 times.
Replace airbag module and, if necessary, seat cover with upholstery
Driver's airbag
Components
Airbag module
Steering Wheel
Steering column (if damaged)
Procedure
Replace faulty components
Replace steering wheel
Front-passenger airbag
Components
Airbag module
Dashboard trim panel (must be replaced with vehicles without replaceable airbag cover!)
Supporting tube (if damaged)
Procedure
Check components; replace if necessary
Side airbag, front/rear
Components
Airbag module
Door trim panel
Door in white
Seat
Procedure
Head airbag
Components
Airbag module
A-pillar trim panel
Roofliner
Cover, B-pillar (if damaged)
C-pillar trim panel (if damaged)
Connection/mount (on side frame)
Procedure
Knee airbag
Components
Trim panel (driver's side)
Lower section of glove box
Knee protection(Driver- and passenger's side)
Procedure
Passive knee protection
Components
Trim panels (driver's side)
Glove box incl. knee protection (passenger's side)
Procedure
Check retaining elements
32 34 020 Removing and installing/replacing airbag unit
Warning!
airbag unit.
Comply with safety regulations for handling components with
gas generators.
Do not exert any force on the airbag unit.
Use only specified tools for releasing the airbag unit.
Note: Incorrect handling may result in triggering of the airbag unit
and thereby cause serious injury.
Important!
Steering wheel must be replaced if airbag unit has been triggered!
Follow procedure after airbag triggering.

Disconnect battery negative lead
Release screws (Torx T30) on both sides.Installation:

Make sure electrical leads are correctly positioned.
Warning!
Danger of injury!
Airbag unit may only be set down with the airbag itself facing
upwards.
Press down lock (1) and disconnect plug (2).
Remove airbag unit.
Replacement:
Disconnect plug connections on airbag unit and remove connecting
cable.
Installation:
Connect plugs to connections of same colour on airbag unit.
32 34 020 Removing and installing/replacing the airbag unit (sports steering
wheel, inserted airbag unit)
Warning!
airbag unit.
Comply with safety regulations for handling components with
gas generators.
Do not exert any force on the airbag unit.
Use only specified release tool for the airbag unit.
Note: Incorrect handling may result in triggering of the airbag unit
and thereby cause serious injury.
Attention!
Steering wheel must be replaced if airbag unit has been triggered!
Follow procedure after airbag deployment.

Disconnect battery earth lead
Installation note:
When installing a new airbag unit (see table below), the available ground
spring (1) must be removed from the base plate of the steering wheel.
Pull off spring (1) from screw.
Omitting the ground spring (1) on new airbag units is not a safety hazard.
Introduction dates of new airbag units:
E46: 01/2002
E53: 02/2003
E39: 03/2002
Insert a screwdriver through the opening on the rear side of the steering
wheel and press on the lock. In the event of a spring resistance, press
the lock up to the limit position and simultaneously pull away the airbag
unit (1) from the steering wheel.
Repeat the process on the opposite side.
The process on the next image is illustrated without the airbag unit to
make it clearer.
Use the screwdriver (2) to press on the lock (1).
Installation note:
Make sure electrical leads are correctly positioned.
Insert the airbag unit into the locks with the hooks and press it into the
steering wheel.
Warning!
Danger of injury!
Airbag unit may only be set down with the airbag itself facing
upwards.
Unlocking the airbag plug connection:

Lever out the lock (1) with a screwdriver.
Open the locks (1) and pull off the connector.

Remove airbag unit.
Installation note:
Connect plugs to connections of same colour on airbag unit.
72 00 ... Safety regulations for handling airbag system components
Failure to comply with warnings and repair instructions may result in accidental activation and cause
physical injury!
This applies in particular to components with gas generators:
Airbag modules (driver's/front passenger airbags, side airbags)
Buckle/belt tensioner
Head airbag (ITS)
The gas generators are pyrotechnic objects of danger classification T 1. The handling, transport and storage of
unignited gas generators is subject to the German ”law relating to the use of explosives” (Explosive materials
law of 13/09/1976).
The appropriate trade inspection office must be notified at least 2 weeks in advance before pyrotechnic
objects are handled for the first time.
Here the relevant authority must be notified in writing of the person responsible, e.g. dealership owner, holder
of general power of attorney or if necessary workshop supervisor. A certificate of qualification, i.e. specific
training, is not required for the person responsible.
The regulations listed refer to the Federal Republic of Germany. In all other countries, the relevant legislation
and regulations must be observed in each case. Country-specific legal regulations that go beyond this
information or court decisions based thereon must be followed in each case or given precedence over these
regulations.
1. Dismantling and assembly
Inspection, testing and installation work may only be carried out by properly qualified personnel at BMW
Service.
Work on components of the airbag system should only ever be carried out with the battery disconnected,
the negative terminal post covered and the plug connection of the cable leading to the gas generator
disconnected. If only the battery is disconnected, it is absolutely essential to adhere to the specified
waiting period:
30 minutes for vehicles up to 9/93;
1 minute for vehicles from 9/93
In the event of breaks in work, a component with a gas generator that has been removed must be
secured against access by other persons.
Individual components must never be repaired. Instead, always replace them.
Do not treat airbag system components with cleaning agents or grease.
Components of the airbag system must not be exposed to temperatures in excess of 75 °C.
Components of the airbag system, also diagnosis electronics, which have been dropped from a height in
excess of 0.5 m must not be refitted in the vehicles.
Before being installed, the components of the airbag system (also diagnosis electronics) must be
visually inspected for damaged and if necessary replaced.
Airbag system components may only be tested electrically while installed and such test may only be
carried using the BMW SERVICE TESTER / DIS.
Danger of injury!
The airbag module may only be set down with the cushion (airbag) facing upwards.
Otherwise the alternator will be thrown upwards if it is ignited.
Do not point the ignition squib of a gas generator at other persons.
Components with gas generators must not be fired when removed but must rather be disposed of by
special disposal companies or sent to BMW in the packaging of the new parts.
When carrying out straightening and welding work with an electric welder:
Disconnect battery
Cover negative terminal (post)
Disconnect plug connections to the gas generators so that the voltage supply to the gas
generators is cut off in each case
When removing a fired airbag module, avoid all contact with the skin - wear gloves. In the event of skin
contact - wash with water.
2. Transport
Components with gas generators must be sent off in the packaging of the new components.
3. Storage
Observe the regulations of the relevant trade supervisory authority and the applicable national
regulations.
72 00 ... Safety regulations for handling components with gas
generators
It is essential to comply with the regulations as specified in the law relating to the use of explosives when
working on airbag units and seat belt tensioners.
Airbags, seat belt tensioners etc. are pyrotechnical objects. Pyrotechnical objects are assigned to different
danger classes on the basis of the quantity of propellant that they contain. The assignment can be
ascertained from the identification marking on the product:
Important!
Failure to comply with the warning notices and repair instructions for gas generator components can
cause accidental deployment and result in injury and vehicle damage!
This applies in particular to the following components:

Head airbag
Active knee protection
1. Regulations
The regulations quoted in the following refer to the Federal Republic of Germany.
In all other countries, the relevant legislation and regulations must be observed in each case. Country-specific
legal regulations that go beyond this information or court decisions based thereon must be followed in each
case or given precedence over these regulations.
The following components used by BMW:
Pyrotechnical restraint systems are subject to danger class PT1
Gas generators are pyrotechnical objects belonging to danger class T1
Handling, transporting and storing non-fired gas generators are subject to the ”Explosive Materials Act” (law
relating to the use of explosives dated 13/09/1976).
The relevant trade supervisory authority must be notified at least 2 weeks before pyrotechnical objects are
handled for the first time. Here the relevant authority must be notified in writing of the person responsible (e.g.
dealership owner, holder of general power of attorney or if necessary workshop supervisor). A certificate of
qualification, i.e. specific training, is not required for the person responsible.
2. Dismantling and installation
Inspection, testing and installation work may only be carried out by expert trained personnel in BMW
Service.
disconnected. If only the battery is disconnected, the following prescribed waiting period must be
observed without fail:
30 min. for vehicles up to 9/93
1 min. for vehicles from 9/93 onward
Airbag system components, including electronic diagnostic components, which have been dropped from
heights in excess of 0.5 m must not be reinstalled in the vehicles.
Do not remove components of the airbag system from the original packaging until immediately before
they are to be installed in the vehicle.
Before installing, subject components such as housing, connector pins ,etc. of the airbag system
(including diagnosis electronics) to a visual inspection for damage and replace if necessary.
Airbag system components may only be electrically tested while they are installed and only with the
BMW ISTA.
Danger of injury: The airbag module may only be set down with the airbag itself facing upwards.
Components with gas generators must not be fired while they are removed. They must be disposed of
by special disposal companies or returned to BMW in the packaging of the new components.
Disconnect battery
Avoid all contact with the skin when removing a fired airbag module ‐ wear gloves. Wash with water after
contact with the skin.
3. Transport
4. Storage
regulations.
32 13 006 Bleeding power steering unit
Warning!
Important!
hydraulic system.
Using contaminated equipment to add fluid may introduce dirt
particles into the fluid reservoir and significantly reduce the service
life of the power steering system. Do not use any filler funnels or
similar!
The fill level may only be checked or adjusted when the engine is
stopped! The fluid temperature should be approx. 20 °C here.
Ensure that the cap is fully screwed in prior to the fill level check.
Note:
To avoid mix-ups when filling with hydraulic fluid, mark the fluid reservoirs
or their caps with identification marks.
ATF Automatic transmission fluid

CHF Pentosin CHF11S
1. Thoroughly clean fluid reservoir and its immediate surroundings

2. Check and correct fill level
Note: The fill level can come to rest above the ”MAX” mark when
the engine is at normal operating temperature. This is dictated by
the design in that the marking on the dipstick is referred to a fluid
temperature of 20 °C. With the engine at normal operating
temperature (approx. 50-60 °C fluid temperature) adjust a fill height
10 mm above the ”MAX” mark. Do not under any circumstances
draw off the fluid to the ”MAX” mark when the engine is at normal
operating temperature.
Hydraulic fluid: BMW Service Operating Fluids
3. Start engine
4. Turn steering wheel left and right twice in each case up to full lock; if
necessary, top up hydraulic fluid (e.g. if hydraulic system is
completely drained)
5. Move steering wheel to straight-ahead position and turn off engine
6. Check and correct fill level with engine stopped
7. Check hydraulic system for leaks
32 41 ... Instructions for removing and installing ear clips

32 1 260
Note:
The work steps are show on assorted components.
Ear clip must always be replaced.
To remove an ear clip, place special tool 32 1 260 at right angles to ear
and cut ear open.
The ear clip can be fitted not only axially but also radially after the hook
fastener has been opened.
Attach hook fastener and press ear together with special tool 32 1 260 .
The diagonal cutting pliers of special tool 32 1 260 can be used in areas
which are difficult to access.
Important!
Gap (A) max. 1 mm!
32 41 ... Instructions for using special tool 32 4 000

32 4 000
32 4 004
32 4 005
32 4 006
32 4 011
32 4 012
Depending on the pressure hose connection on the pump, the special

tool 32 4 000 must be assembled.
1 = Connection, pump
2 = Connection, steering gear
Pressure hose connection to pump with M14 x 1.5 banjo bolt:

Mount special tool 32 4 004 with banjo bolt (1) M14 x 1.5 and 2 sealing
rings to special tool 32 4 000 .
Mount special tool 32 4 011 to pump and connect special tool 32 4 004 .
Mount special tool 32 4 006 / 32 4 012 to special tool 32 4 000 and
connect pressure hose with banjo bolt M14 x 1.5 and 2 sealing rings.
Pressure hose connection to pump with M16 x 1.5 banjo bolt:

Mount special tool 32 4 005 to pump and connect special tool 32 4 004 .
Mount special tool 32 4 006 to special tool 32 4 000 and connect
pressure hose with banjo bolt M16 x 1.5 and 2 sealing rings.
Pressure hose connection to pump with M16 x 1.5 retaining screw:
Connect special tool 32 4 004 to pump.
Mount special tool 32 4 006 / 32 4 005 to special tool 32 4 000 and
connect pressure hose.
32 41 ... Notes on hydraulic line with quick-connect coupling
1) Quick-connect coupling with ID marking
Removing:
Push quick-connect coupling (1) against pipe (4) (thereby relieving strain on spring (2)).
Press plastic ring (3) into quick-connect coupling (1) and remove coupling (1).
Assembly:
Markings (K) on coupling (1) and pipe (4) must be flush.
Push quick-connect coupling (1) onto pipe (4) until a ”click” can clearly be heard.
To check that quick-connect coupling (1) has been installed correctly, pull it back forcefully.
2) Quick-connect coupling with indication pins

Removing:
Press plastic ring (2) into quick-connect coupling (1) and remove coupling (1).
Assembly:
When replacing hydraulic line: remove transportation lock (T).
Push quick-connect coupling (1) onto pipe (3) until both indication pins (4) can be seen and felt to point outwards at outside
diameter of housing.
To check that quick-connect coupling (1) has been correctly fitted, feel indication pins (4) at outside diameter of housing.
When correctly seated, indication pins (4) cannot be pressed into housing.
Important!
Coupling is not correctly engaged if both indication pins (4) fail to protrude from housing. Leakage is thus unavoidable.
32 41 380 Removing and installing or replacing oil cooler/cooling coil for
power steering
Important!
hydraulic system.
Seal off hydraulic lines with plugs.

Disconnect quick-connect couplings on cooling coil
Remove radiator.
Remove cooling coil from radiator.
After installation:
Top up hydraulic fluid and bleed system
32 41 060 Removing and installing power steering vane pump (M47)
Important!
hydraulic system.

Slacken drive belt and remove from belt pulley
Remove panel for engine on left (refer to ”Removing and
installing air intake manifold”)
Disconnect cooler return line (1) from fluid reservoir.

Disconnect pressure line (2) from vane pump.
Installation:
Remove pulley.
Unfasten screws.
Release nuts and remove pressure transducer.

Unfasten screws.
Remove vane pump.
After installation:
32 41 060 Removing and installing vane pump for power steering (M47TU)
Important!
hydraulic system.

Slacken drive belt and remove from belt pulley
Disconnect return line (1) from fluid reservoir.

Disconnect pressure line (2) from vane pump.
Installation:
Remove pulley.
Release nut and remove ground cable.
Unfasten screws.
Remove vane pump.
After installation:
32 41 100 Removing and installing/replacing belt pulley on vane pump for
power steering
Note:
Carry out preliminary work as described in the document ”Replacing drive
belt”.
Slacken bolts (1)

Relieve tension on drive belt and remove from belt pulley (2).
Unscrew bolts (1) and remove belt pulley (2).
Installation:
Lettering on belt pulley (2) must point forwards.
32 41 061 Replacing power steering vane pump
Important!
hydraulic system.
After installation:

Check function of vane pump
Remove vane pump
Release screws (1).

Remove belt pulley (2).
Installation:
Lettering on belt pulley (2) must point forwards.

temperature.
Installation note:
curing)
32 ... . Overview of steering
Safety precautions and general

information
1 Tie rod end / tie rod / gaiter 8 Steering column

2 Cooling coil 9 Overview of steering wheel/casing components
3 Power steering gear 10 Steering angle sensor
4 Auxiliary steering pump 11 Sleeve for steering spindle
5 Fluid reservoir 12 Steering spindle lower section
6 Flexible disk/double joint/universal joint 13 Adjustment work
7 Interlock cable 14 Troubleshooting
32 .. .. Overview of steering wheel / casing components / lock cylinder
1 Steering wheel 4 Lock cylinder

2 Airbag unit 5 Lower steering column casing
3 Upper steering column casing 6 Control lever
32 00 ... Test conditions for chassis/wheel alignment check
Observe the following test conditions prior to the chassis/wheel alignment check:
1. Only BMW approved wheel and tyre combinations are installed on the vehicle.
2. Correct tread depth. The tread depth for each axle may differ from left to right by max. 1‐2 mm.
3. Correct tyre pressure (see label on vehicle).
4. All chassis and suspension components must be technically OK.
5. Condition of suspension and shock absorbers OK: Visually inspect for breakage, etc.
6. Vehicles with self-levelling suspension: Pull fuse of air supply system so that there is no controlling down
or up.
Headaches
Dizziness
Stomach aches
Vomiting
Diarrhoea
Cramps/fits
Unconsciousness

or mugs)
First aid measures:

immediately.
Situation:
E32, E34, E38, E39: With the rear spring struts with self-levelling suspension, a slight oil leak usually exists at
the piston rod. These spring struts are permitted to be wet with oil over a maximum of half the shock absorber
length on the outer tube, i.e. they are permitted to ”sweat”.
Effect:
Procedure:
Parts Department)
33 00 ... Instructions (chassis components made of aluminium)
Due to the chemical and corrosion characteristics of aluminium, always comply with the following points when
handling aluminium components:
- Do not bring into contact with battery acid!
- Do not clean with wire brushes made of brass or iron! Always use wire brushes with stainless steel bristles!
- Do not expose to flying sparks when grinding/separating! Cover components!
- Do not strike with steel welding splashes! Cover components!
- Do not expose to temperatures > 80 Â°C, even for brief periods! Temperatures in paint facilities do not have
the same impact
16 00 ... Layout of fuel supply system (KVA)
Layout / function description of fuel supply system (KVA)
1 Filler pipe with unleaded flap and non-return 9 Vent line, right, for service venting
flap
10 Vent line from expansion tank to activated carbon
2 Fuel tank canister
3 Fill level sensor, left 11 Scavenging air line to engine
4 Fill level sensor, right, with electric fuel pump 12 Evaporation line to atmosphere
(EKP)
13 Fuel feed line to fuel filter
5 Expansion tank
14 Return line from engine
6 Carbon canister
7 Vent line for refuelling
8 Vent line, left, for service venting
Functional description of fuel supply system

Refuelling: During refuelling, the fuel is poured through the filler pipe into the right half of the tank. When the
right half of the tank is full, further fuel pours into the left half of the tank. The tank is now
completely full.
An unleaded flap is incorporated in the filler pipe at the top to ensure that only pump nozzles for
unleaded fuel can be inserted.
A non-return flap is located at the bottom end of the filler pipe to prevent fuel from sloshing back
and thus make refuelling easier.
Fuel The electric fuel pump (with suction strainer) draws fuel from the surge chamber and delivers it
delivery: to the fuel filter. The fuel flows from the fuel filter to the engine.
The fuel return line runs from the engine to the left fill level sensor. An overflow line is attached
to the left fill level sensor.
The overflow line integrated in the tank returns the fuel to the right tank half into the surge
chamber. This guarantees a safe fuel supply even when the car is in extreme positions. I
The overflow line incorporates a suction jet pump which pumps the fuel from the left to the right
tank half.
Fuel tank During refuelling, the air displaced from the fuel tank is routed through a vent line to the filler pipe.
ventilation:
There are service vent lines mounted to the left and right sides of the tank. The left vent line
leads to the underside of the expansion tank. The right service vent line is connected via a loop
leading to the left side of the tank to the top of the expansion tank. The loop in the right service
vent line prevents the expansion tank from filling up when the car is in extreme positions. Both
service vent lines serve the purpose of dynamic tank venting when the car is moving.
When the engine is at a standstill, the fuel vapours displaced from the fuel tank are routed
through the expansion tank to the activated carbon canister. The activated carbon in this
canister absorbs the hydrocarbons and clean air is discharged to atmosphere.
When the engine is running at normal operating temperature, the tank venting valve in the
engine compartment is opened in certain operating states. As a result, the partial vacuum
prevalent in the intake pipe causes fresh air to be drawn into the activated carbon canister,
thereby enabling the activated carbon to regenerate. The fuel vapours are drawn in and burned
by the engine.
The expansion tank incorporates a rollover valve which, in the event of the car rolling over,
closes the connection between expansion tank and activated carbon canister, thereby
preventing the fuel from spilling out.
Important!
Install Helicoil thread inserts so that they are flush with the original
thread.
Note:
Damaged threads in the frame side member may be repaired with Helicoil
thread inserts. Comply with the procedure described in the example.
31 00 ... Notes on wheel bearing replacement following accident
damage
Wheel bearing facts:
In the event of accidents or driving conditions similar to accidents, shock-like loads to the wheel bearing units
can cause slight damage to the bearing track. Despite initial running without noise, with continued use, this
results in later noise generation at the wheel bearing.
Procedure:
The wheel bearing must be replaced on the damaged side of the axle if one or several of the following points
apply:
Visible or noticeable damage to the wheel bearing
Rolling noises, radial/lateral runout on the wheel bearing
Permissible tolerance for the wheel alignment is exceeded and no longer adjustable without the
exchange of additional components
Wheel rims (major damage) and simultaneous negative result for wheel alignment
Spring struts, swivel bearings, wheel carriers
Wishbones
Body-side screwing/attachment points for wheel guide/control components
Track rods
This guideline is binding for all accident repairs to BMW, MINI and Rolls-Royce vehicles!
33 32 .. Overview of control arms with rubber mounts
1 Rubber mount in control arm, top 6 Rubber mount in trailing arm at front
2 Control arm, top (left/right) 7 Control arm, bottom (left/right)
3 Ball joint in trailing arm 8 Rubber mount in control arm, bottom
4 Rubber mount in trailing arm 9 Adjustment work
5 Trailing arm (left/right)
33 10 ... Overview of final drive/output shafts
Safety precautions & general information
1 Final drive 4 Cover gasket

2 Drive flange / shaft seal 5 Drive flange / shaft seal
3 Output shaft (left/right) 6 Output shaft gaiters
33 31 ... Overview of rear axle carrier with rubber mounts
1 Rear axle carrier 4 Rear axle carrier rubber mount, front

2 Rear axle carrier rubber mount, rear 5 Rear differential rubber mount, front
3 Rear differential rubber mount, rear
Warning!




Risk of damage!
33 ... . Rear axle layout
Safety precautions and general information
1 Final drive / output shafts 6 Arm

2 Rear axle carrier 7 Stabilizer bar / stabilizer links
3 Shock absorber 8 Adjustment work
4 Coil spring 9 Troubleshooting
5 Wheel bearing / drive flange hub 10 Testing
33 00 ... Rear axle: wheel/chassis alignment check must be carried out after
the following work
Rear axle carrier to body
Bearing block to trailing arm / body
Upper control arm to rear axle carrier / trailing arm
Lower control arm to rear axle carrier / trailing arm

1. Rear axle carrier / rubber mount
2. Lower control arm / rubber mount
3. Trailing arm / rubber mount / bearing block / ball joint
4. Upper control arm / rubber mount / ball joint
Danger of injury!
Impaired sight

First aid measures:

Warning!
Recycling:

ground.
00 11 ... Checking/topping up oil level in rear differential
Important!
Risk of damage!
To avoid serious damage to the rear differential, it is essential to
use only approved gear oils in the differential.

Check oil level.
If necessary, pour in rear differential oil up to lower edge of opening for oil
filler plug (1).
Installation:
A. Oil filler plug with sealing ring:
B. Oil filler plug with O-ring:
Replace oil filler plug (2).
00 11 259 Oil change in rear differential incl. used oil disposal
Note:
Observe following instructions and torques for variants (A & B).
A. Replace sealing ring (1) after releasing.
B. Replace screw plug (2) with O-ring after releasing.
Warning!
Risk of burning if exhaust system is touched!
Important!
Risk of damage!
To avoid serious damage to the rear axle differential, it is essential
to use only approved transmission oils in the rear axle differential.
Note:
The oil does not need to be changed in rear differentials carrying the
”Life‐Time‐Oil” sticker.
Only change oil when rear differential is at normal operating temperature.
Recycling:
Catch and dispose of emerging differential oil.
Oil drain plug present:

Place oil collecting apparatus underneath.
Open plug (1).
Open plug (2).

No oil drain plug:
Open plug (1).
33 10 ... Rear differential: Assignment to model series
Model Engine Rear Remark
series differential
E46 M43TU, M52TU 320, M54 320 with automatic transmission, 168K
N4x
M47, M47TU, M52TU 323/328, M54 325/330 with manual 188K
transmission, M56
M57 330, M57TU 330 215K
S54 210N with variable M
differential lock
E46/16 M54, M57 188K
N = Normal drive
K = Compact drive
33 10 010 Removing and installing/replacing rear differential

33 4 420
Important!
Use only approved rear differential oils!

Remove tension strut and insert bolts for rear axle carrier at front
until contact is made
Remove propeller shaft on final drive.
Remove output shaft from rear differential at both ends and tie back
Except E46/5 (Compact): Remove rear stabilizer
E46/5 (Compact):
Remove spare wheel.
Release screws (1) on spare wheel holder.
Tilt spare wheel holder (1) downwards.
Warning!
Danger of injury!
Failure to comply with the following instructions may result in the
vehicle slipping off the lifting platform and critically injuring other
persons.
When supporting components, make sure that

the vehicle can no longer be raised or lowered
the vehicle does not lift off the locating plates on the lifting
platform
Support rear differential with workshop jack and special tool 33 4 420
.Important!
Observe gap between special tool 33 4 420 and dust plates (1).
To avoid grinding noises, make sure the dust plates (1) are not
damaged (e.g. bent).
Unfasten screws.
Release nut and pull out bolt towards middle of vehicle.

Slowly lower workshop jack and remove rear differential towards rear.
Important!
Adhere to the following installation sequence in order to prevent
distortion of the rear differential during installation and thereby avoid
potential complaints about noise.
1. Install rear differential with workshop jack and special tool 33 4 420 .
2. Insert bolts (1) (do not tighten down)
3. Insert bolt (2), replace and screw on nut (3) (do not tighten down).
4. Lower workshop jack and place to one side
5. Tighten screws (1)
6. Tighten screw (2)
Replacement:
If necessary, modify vibration damper with bracket.
After installation:
Replacement only:
Add rear differential oil
Check rear differential oil level, correct if necessary
33 11 ... Removing and installing/replacing vibration damper
Vibration damper with bracket:

Release bolts (1) and remove vibration damper with bracket.
Vibration damper:
Release bolts (1).
Remove retaining plate and vibration damper (2).
33 11 151 Replace the radial shaft seal for the left or right drive flange

00 5 010
00 5 500
32 1 060
33 1 308
33 3 400
33 4 240
33 4 250
33 5 030
33 4 320
33 4 330
33 4 340

Remove drive flange on the rear axle final drive.
If necessary, press of dust plate.
Pull out the radial shaft seal with special tools 00 5 010 and 32 1 060 /
33 1 308 .
Coat the housing from the rear axle differential and sealing lips of the new
radial shaft seal with approved final drive transmission oil.
Drive in the new radial shaft seal with the following special tools
(depending on the rear axle differential/outer diameter) up to the limit
position or up to the rim offset (M3).
00 5 500 + 33 3 400 (or 33 4 320 ): 168K/L - 78x44x10
00 5 500 + 33 4 240 (or 33 4 330 ): 188K/L/LW - 90x44x10
00 5 500 + 33 4 250 (or 33 4 340 ): 215K/L/LW, 220K to 230K -
100x50x10
M3: 33 5 030 : 210, 215 with lock - 76x50x10
Observe the rim offset (dimension A = 19.5 mm) for the radial shaft
seal.
After installation:
Correct the transmission oil level / change the final drive
transmission oil.
33 11 091 Replacing drive flange on left or right of final drive
Warning!
Risk of burning on the exhaust system!
Important!
When replacing the drive flange, you must also replace the shaft
seal!

Remove output shaft from rear differential and tie back
Knock out drive flange or press out with two suitable tools (only on
differential without dust cover).Installation:
Insert drive flange and rotate until spline on flange meshes with teeth on
differential bevel gear.
Press drive flange in further until circlip locates with an audible click.
Install retaining ringÂ (1).Installation:

Only if the retaining ring was fitted in the rear differential: twist retaining
ring until both ends settle into the groove.
Clean shaft seal race on drive flange thoroughly.
Coat drive flange at contact face of shaft seal with approved rear
differential oil.
Replacement:
Replace shaft seal.
After installation:
Correct gearbox oil level/change differential oil
33 11 271 Replacing rear cover gasket on rear differential
Important!
In event of oil loss, always check rear differential for traces of wear
and damage.

Drain and catch rear differential oil
Remove rear differential
Note:
Read and comply with document ”Rear differential: Assignment to model
series”.
Select rear differential:

168K
188K
210 with lock
215K
After installation:
Add rear differential oil
33 11 ... Replacing rear cover gasket on rear differential (168K)
Important!
To avoid leaks from the rear differential cover, do not use a paper
gasket in cars with liquid gaskets!
To prevent the differential oil from foaming over, make sure that no
remnants of the liquid gasket are pressed into the rear differential
housing.
Release screw (1).

Tightening torque (M10x60) 33 11 1AZ.
Unscrew screws (2).
Remove cover.
If necessary, remove remnants of liquid gasket with scraper.
Clean sealing face on cover and rear differential.
Installation:
If a paper gasket was fitted, a paper or liquid gasket can be used.
The liquid gasket can be found in Main Group 33 in the Electronic Parts
Catalogue.
Important!
housing.
Release screws (1).

Unscrew screws (2).
Remove cover.
Installation:
Catalogue.
Important!
housing.
Release screw (1).

Unscrew screws (2).
Remove cover.
Installation:
Catalogue.
33 11 021 Replacing shaft seal for input flange on final drive

00 5 010
00 5 500
23 0 020
23 1 300
23 1 302
23 1 303
31 2 101
31 2 102
31 2 103
31 2 104
33 1 150
33 1 341
33 3 390
33 3 440
33 3 470
33 3 480
33 3 490
Important!
Use only approved gear oils.
the rear differential!

Remove propeller shaft from rear differential drive flange,
remove complete propeller shaft if necessary
Removing drive flange:

Lift out retaining plate.
Mark position of collar nut (1) on drive shaft with peening tool.
Brace drive flange with special tool 23 0 020 and release collar nut.
Note:
Read and comply with document ”Rear differential: Assignment to model
series”.
210N, 215K, 220K:

Remove drive flange with special tools 31 2 101 , 31 2 102 , 31 2 103 /
31 2 104 .
168K, 188K:
Remove drive flange with special tool 33 1 150 .
Replacing shaft seal:

Withdraw shaft seal with special tool 00 5 010 .
Drive in new shaft seal with following special tools (depending on rear
differential) as far as it will go.
168K: Use special tools 00 5 500 and 33 3 390
188K: Use special tools 00 5 500 and 33 3 470
210N, 215K, 220K: Use special tools 00 5 500 and 33 3 440
Installing drive flange:

Coat sealing lips of shaft seal and sealing surface of drive flange with
differential oil.
Fit drive flange.
Press on drive flange with special tools 23 1 300 , 33 1 341 and 23 1 303 ,
if necessary 23 1 302 until collar nut can be screwed on.
Important!
Do not under any circumstances tighten down collar nut beyond
marker points in order to avoid damaging the clamping sleeve.
Tighten down collar nut (1) to point where marker points are aligned.
Drive in new retaining plate with following special tools (depending on

rear differential) as far as it will go.
168K, 188K: Use special tools 00 5 500 and 33 3 480
210N, 215K, 220K: Use special tools 00 5 500 and 33 3 490
After installation:
Change rear differential oil
33 11 521 Replacing the dust plate on the rear axle differential
(input flange removed)
TECHNICAL INFORMATION
The work must be performed with care to prevent component damage.
1 – Removing the dust plate
Different variants may be installed depending on the vehicle equipment.
▶ Version A: Removing the dust plate

Release and remove the dust plate (1) with the help of a hydraulic press (2)
and the special tool in the direction of arrow from the input flange (3).
▶ Version B: Removing the dust plate

Release and remove the small dust plate (1) and the large dust plate (2)
using hydraulic press (3) and special tool from input flange (4) in the
direction of the arrow.
2 – Installing dust plate
Different variants may be installed depending on the vehicle equipment.
▶ Version A: Installing dust plate

Renew dust plate (1).
Parts: dust plate
Press the dust plate (1) onto the input flange (2) with a hydraulic press and
the special tool 0 492 261 (33 3 201) in the direction of arrow.
▶ Version B: Installing dust plate

Renew the large dust plate (1).
Parts: Large dust plate
Press the large dust plate (1) using hydraulic press (2) and special tool in
the direction of the arrow on input flange (3).
Renew the small dust plate (1).

Parts: Small dust plate
Press the small dust plate (1) using hydraulic press (2) and special tool on
the input flange in the direction of the arrow.
Additional Information
Overview of Special Tools

0 492 261 (33 3 201) Bush
Used in step 2
Common
For accommodating control arm when pressing out
Usage rubber mount Series: E31 Discontinued, only available
via complete tool
Included in the tool 0 492 260
or work
Storage location B13
Replaced by
In connection with
SI-Number
33 17 004 Replacing all rubber mounts for front final drive suspension
Remove final drive,

refer to 33 10 010.
Remove rubber mount with special tools 33 3 314 / 315 / 361 / 362 and a
nut M12 (1).
Caution!
Observe installation position of rubber mount:
Fig. A = Protrusion (A) in direction of travel, rear

Fig. B = Openings (1) in transverse vehicle direction
Coat new rubber mount and bearing bush with Circolight, refer to BMW
Parts Service.
Install rubber mount (1) with special tools 33 3 314 / 315 / 362 and
33 4 173 up to stop.
33 17 005 Replacing rubber mount for final drive mounting at rear

33 3 314
33 3 315
33 4 181
33 4 182
33 4 183
33 4 184
Note:
M3: Rubber mounts cannot be replaced -> final drive cover must be
replaced.
Remove final drive.

Remove rubber mount with special tools 33 3 314 / 33 3 315 and
33 4 181 / 33 4 183 .
Caution!
Observe installation position of rubber mount.
Rubber mount and bearing bush free of grease!
Installation position of rubber mount up to 8/99:

1. Arrow of lettering "TOP" must point upwards
2. Lettering "TOP" must be located in left direction of travel
Installation position of rubber mount from 8/99:
1. Arrows of lettering "TOP" must point upwards
2. Lettering "TOP" must be located in right direction of travel
Install rubber mount (1) with special tools 33 3 314 / 33 3 315 and
33 4 182 / 33 4 184 up to stop.
33 21 ... Pressing output shaft out of drive flange and drawing in (output
shaft removed from rear axle final drive)

33 2 111
33 2 115
33 2 116
33 2 117
33 2 118
33 2 119
33 2 160
33 2 201
33 2 202
33 2 203
33 2 205
33 2 206
33 2 207
33 5 070
Warning!
Risk of injury!
It is not permitted to use the impact screwdriver to press out and
draw in the output shaft.
Important!
Risk of damage!
To avoid damaging the output shaft and adjoining parts, it is
essential during the pressing-out process to repeatedly check and
if necessary correct the position of the output shaft.
Important!
To avoid damaging the dust boot, use special tool 33 2 160 to
press out and draw in the output shaft after removing the brake disc.
Note:
Special tool 33 2 200:
Secure output shaft against falling out.
Screw on special tools 33 2 203 , 33 2 207 and 33 2 201 with all wheel
bolts to drive flange.
Press output shaft out of drive flange; in so doing, grip basic
body 33 2 201 with special tools 33 2 202 and 33 5 070 .
Important!
No oil permitted on shaft journal thread!
Lightly oil spline teeth of output shaft.

Insert output shaft into drive flange.
Screw special tool 33 2 205 / 33 2 206 onto output shaft.
Mount special tool 33 2 201 with three wheel bolts to drive flange.
Draw in output shaft with special tool 33 2 205 up to stop; in so doing,
grip basic body 33 2 201 with special tools 33 2 202 and 33 5 070 .
Special tool 33 2 100:

Secure output shaft against falling out.
Screw on special tools 33 2 111 , 33 2 117 and 33 2 116 with all wheel
bolts to drive flange.
Press output shaft out of drive flange; in so doing, grip basic
body 33 2 116 with special tools 33 2 202 and 33 5 070 .
Important!
No oil permitted on shaft journal thread!
Lightly oil spline teeth of output shaft.

Insert output shaft into drive flange.
Screw special tool 33 2 118 / 33 2 119 onto output shaft.
Mount special tool 33 2 116 with three wheel bolts to drive flange.
Pull in output shaft with special tool 33 2 115 up to stop; in so doing, grip
basic body 33 2 116 with special tools 33 2 202 and 33 5 070 .
33 21 001 Removing and installing / replacing left output shaft
Warning!
Scalding hazard!
Only perform the following tasks after the vehicle has cooled down.

Remove intermediate pipe with catalytic converter
E46/5 (Compact): Remove entire exhaust system
Note:
The subsequent procedure is described in the document ”Removing and
installing/replacing right output shaft”.
33 21 002 Removing and installing / replacing right output shaft
Apply handbrake.
Remove rear wheel.
Unscrew collar nut (1).
Installation:
Replace collar nut, apply a light coating of oil to contact surface and
tighten down.
Secure collar nut (1) by peening at flat areas of output shaft.
Release rear stabilizer.
Release bolts and remove with washers (1).

Press output shaft off drive flange using a suitable tool; if necessary,
raise trailing arm with workshop jack approx. 20 mm.
Installation:
Before installing output shaft, make sure that drive flange is fully engaged
in rear differential.
Replace bolts and washers (1).
Press output shaft out of drive flange and remove towards center of
vehicle.
33 21 000 Removing and installing/replacing left or right output shaft
Warning!
Risk of burning!
Only perform the following tasks after the vehicle has cooled down.
Engage the parking brake.

Remove rear wheel.
Unscrew collar nut.
Installation note:
Renew the collar nut, apply a light coating of oil to the contact surface and
tighten down.
For convertibles only: Remove the trailing link on the left and right
(reinforcement on spare wheel well).
Lower and, if necessary, remove the rear exhaust system.
Remove the anti-roll bar on the rear axle support and tip down.
Release bolts and remove with shims (1).

Press output shaft off drive flange using a suitable tool; if necessary,
raise trailing arm with workshop jack approx. 20 mm.
Installation note:
Before installing the output shaft, make sure that the drive flange is fully
engaged in the rear axle differential.
Replace bolts and shims (1).
Press output shaft out of drive flange and remove towards centre of
vehicle.
33 21 ... Ribbed teeth
Important!
Bolts with ribbed teeth must be replaced after they have been
released!
33 31 503 Lowering/raising rear axle carrier

33 4 420
Warning!
Danger of injury!
persons.
Read and observe the information on load distribution in the

lifting platform operating instructions.
Before lowering/removing the rear axle carrier, it is essential to

place a minimum load of 100 kg in the luggage compartment to
prevent the vehicle from toppling/slipping off the lifting platform!

platform
Note:
If the rear axle carrier is detached from the body, it is necessary after
reinstallation to carry out a wheel/chassis alignment check.
After installation:

Convertible: Remove tension strut
M3:Remove V-strut
Compact: Remove holder for emergency wheel
Remove stabilizer from rear axle carrier
Remove propeller shaft from rear differential and tie back
Unclip handbrake Bowden cables in tunnel
sensor
Vehicle with diesel engine: Remove vibration damper with
bracket from rear differential
Support rear differential with workshop jack and special tool 33 4 420 .
Important!
Remove tension strut.
Release screws and remove stop plate.

Lower rear axle carrier.
Note:
inserts.
Check seating of coil springs with spring pads, correct if necessary.
Installation:
Check threads on threaded pins; if necessary, replace damaged
threaded pins.
33 31 000 Removing and installing complete rear axle carrier

33 4 420
Warning!
Danger of injury!
persons.



platform

Convertible: Remove tension struts
M3:Remove V-strut
Compact: Remove holder for emergency wheel
Remove propeller shaft from rear differential and tie back
Disengage handbrake Bowden cables from handbrake lever
and expose up to rear axle carrier
Remove coil springs
sensor
Remove lip on both sides
Disconnect plug connection for pulse generator on both sides
Disconnect plug connection for right brake pad wear sensor.
After installation:
Adjusting handbrake
Important!
Risk of damage!
Brake hose must not be exposed to tensile loads.
Release screw and remove bracket with brake hose.

Disconnect plug connection for right brake pad wear sensor on brake
caliper.
Remove brake caliper on both sides of trailing arm and tie back.
Remove lower control arm on both sides from trailing arm.
Slide brake caliper through between output shaft and control arm and tie
up.
Remove bearing block for trailing arm from body.
Support rear differential with workshop jack and special tool 33 4 420 .
Important!
Remove tension strut.
Release screws and remove stop plate.

Lower workshop jack.
Installation:
inserts.
Installation:
Check threads on threaded pins; if necessary, replace damaged
threaded pins.
33 31 011 Replacing rear axle carrier
Warning!
Danger of injury!
persons.



platform

Remove complete rear axle carrier and if necessary with other
workers assisting set down on a suitable surface
Remove rear differential.

If necessary, remove ride-height sensor with holder from rear axle carrier.
Remove stabilizer bar.
Remove lower control arm on both sides from rear axle carrier.
Remove upper control arm on both sides from rear axle carrier.
Remove trailing arm on both sides with output shaft and upper control
arm.
After installation:
Adjusting handbrake
33 32 .. Overview of control arms with rubber mounts
1 Rubber mount in control arm, top 6 Rubber mount in trailing arm at front
2 Control arm, top (left/right) 7 Control arm, bottom (left/right)
3 Ball joint in trailing arm 8 Rubber mount in control arm, bottom
4 Rubber mount in trailing arm 9 Adjustment work
5 Trailing arm (left/right)
33 32 160 Removing and installing / replacing tension strut for rear axle
carrier

M3:
Remove strut
Remove intermediate pipe with catalytic converter
Remove panel from fuel tank
Release screws and remove heat shield.
Support rear axle carrier at front middle with workshop jack.

Release screws (2).
Release nuts (1) and remove tension strut.
Installation:
33 32 000 Removing and installing complete left or right trailing arm

31 5 220
33 2 160

Remove output shaft
E83: Remove anti-roll bar link from anti-roll bar
Remove brake disc
Detach handbrake Bowden cable on brake shoe expander.
Remove pulse sensor
Only on right side: Remove brake pad sensor
Important!
Check sensor head and line from pulse sensor prior to
Important!
Risk of damage!
Release screw and remove holder with brake hose.

Warning!
Danger of injury!
persons.

the vehicle does not lift off the locating plates on the vehicle
hoist
Remove coil spring.
Secure special tools 31 5 220 and 33 2 160 with wheel studs to drive
flange.
Support trailing arm with special tool 31 5 220 and workshop jack.
Remove bearing support from body.
Remove lower wishbone from trailing arm.
Remove upper wishbone from trailing arm.
After installation:
Adjusting handbrake
33 32 083 Removing and installing/replacing lower wishbone arm
Note:
If the lower wishbone is detached from the rear axle support/trailing arm, it
is necessary after reinstallation to carry out a wheel/chassis alignment
check.
Before adjusting rear axle, always replace eccentric bolts on both
wishbones .

Remove rear wheel
Important!
To avoid having to remove the coil spring, it will be necessary to
support the trailing arm with the workshop jack.
Support trailing arm from underneath using a workshop jack.

Spread cover on lower wishbone and pull off.
Installation:
Opening in cover points upwards.
Important!
When replacing wishbone, always replace eccentric bolts on both
wishbones.
Refer to Adjusting rear axle .
Mark position of eccentric screw (1) to lower wishbone with centre

marks (2).
Carry over marking from old part to new part.
Release nut (1) and remove eccentric washer (2).

Remove eccentric screw towards front.
Installation:
Note insertion direction of eccentric screw.
Replace eccentric screw and carry over marking from old part.
Align eccentric screw by means of marking to lower wishbone.
Fit eccentric washer (2).
Replace nut (1).
Release screw and remove thread plate (1) downwards.
Support rear differential with workshop jack.
Release bolts of rear axle suspension at rear.
Slacken bolts of rear axle suspension at front.
Press rear differential upwards with workshop jack.
Pull out bolt.
Remove lower wishbone at side.
Installation:
Insert thread plate (1) into opening in rear axle support.
Installation:
Weld seam of wishbone must point upwards.
After installation:
Lower workshop jack and remove.
Check that output shaft is correctly seated in rear differential.
33 32 042 Replacing a rubber mount in trailing arm, front

00 8 550
33 3 144
33 3 145
33 3 222
33 3 227
33 3 228
33 3 324
33 3 340
Important!
Rubber mounts with collars must no longer be installed and must be
replaced as pairs with rubber mounts with slots.
Installation note:
must be replaced.
must be replaced.

Remove bearing support
Remove rubber mount with collar:

Insert special tool 00 8 550 at the recesses of the rubber mounts.
Pull out rubber mount with special tools 33 3 324 and 33 3 340 .
Remove rubber mount with slot:
Important!
The arrow on the special tool 33 3 228 must point in the direction of
extraction!
Pull out rubber mount with the special tools 33 3 144 , 33 3 145 ,
33 3 222 , 33 3 227 , 33 3 228 and nut (1).
Install rubber mount with slot:

Mark the trailing arm eye on the outside with a coloured spot (K)
according to the diagram on the left.
Keep rubber mount and trailing arm eye clean and free from oil and
grease.
Important!
Slot in rubber mount must be aligned with the end of the arrow on
the special tool 33 3 228 !
Install and align rubber mount in special tool 33 3 228 .
Important!
The arrow on the special tool 33 3 228 must point to the coloured
point (K)!
Draw in the rubber mount with special tools 33 3 144 , 33 3 145 ,

33 3 222 , 33 3 227 , 33 3 228 and nut (1) until special tool 33 3 228
becomes slack.
Draw in rubber mount to the dimension (A) = 2.5 mm.
After installation:
Check that output shaft is correctly seated in rear axle final drive.
Perform wheel alignment
33 32 044 Replacing a rubber mount/ball joint in the trailing arm for bottom
wishbone

33 3 331
33 3 332
33 3 333
33 3 334
Note:
S54: A ball joint is installed instead of the rubber mount.
Installation note:
must be replaced.
must be replaced.

Remove lower wishbone from trailing arm
Measure protrusion (A) of old rubber mount and note down.

Pull out rubber mount with special tools 33 3 331 , 33 3 332 , 33 3 333
and nut (1).
Draw in new rubber mount (1) with special tools 33 3 332 , 33 3 333 and
33 3 334 to previously determined protrusion (A).
After installation:
Perform chassis / wheel alignment check
33 32 ... Replacing bearing block for front trailing arm

33 3 280

Remove rear wheel
Disconnect plug connection for pulse generator; if necessary,
expose lead up to trailing arm
Only on right side: Disconnect plug connection for brake pad
sensor; if necessary, expose lead up to trailing arm
Important!
Important!
Risk of damage!
Release screw and remove bracket with brake hose.

Mark position of bearing block (1) to body (2) with coloured mark (3); this
simplifies subsequent toe-in adjustment.
Release screws.
Lower workshop jack and pull trailing arm downwards.
Installation:
inserts.
Unfasten nut.
Pull out screw.
Remove bearing block towards top.
Installation:
Installation with special tool: Installation:

Secure special tool 33 3 280 to bearing pedestal with a screw and align to
wheel center. Place bearing block in position and screw down.
Installation without special tool: Installation:

Place tube (1) (length = approx. 500 mm, dia. = 16 mm) flat on bearing
block, secure with screw clamp and align tube center to wheel center.
Screw bearing pedestal down in this position.
After installation:
33 32 ... Replacing both eccentric bolts

Remove rear wheel.
Support trailing arm from underneath using a workshop jack.
Mark position of eccentric washer (2) to control arm.

Release nut (1) and remove eccentric washer (2).
Replace eccentric bolt (4).
Fit eccentric washer (2).
Align eccentric bolt (4) by way of marking on eccentric washer (2) to
control arm.
Note:
Eccentric bolt (4) and eccentric washer (2) must rest between stops (3)
on control arm.
Replace nut (1).

33 32 021 Replacing left or right trailing arm
Note:
If the trailing arm is replaced in vehicles up to 02/2002, this alters the
cable routing for the pulse generator (refer to Replacing rear pulse
generator).
Important!

Remove trailing arm
Remove brake carrier/brake guard plate.
Installation:
Install new wheel bearing.
Detach inner wheel bearing race from drive flange.
After installation:
Adjust handbrake
33 32 525 Replacing one ball joint in the semi-trailing arm (semi-trailing arm
removed)

33 3 331
33 3 332
33 3 333
33 3 334
Measure and make a note of protrusion (A) of old ball joint.
Pull out ball joint with special tools 33 3 331 , 33 3 332 and 33 3 333 .
Keep trailing arm eye and ball joint (1) clean and free from oil and grease.
Draw in new ball joint (1) with special tools 33 3 332 , 33 3 333 and
33 3 334 to previously determined protrusion (A).
After installation:
33 32 681 Replacing one rubber mount in lower control arm (control arm
removed)

33 3 351
33 3 352
33 3 353
33 3 354
Attach special tool 33 3 354 between both control arms.

Press rubber mount with special tools 33 3 351 and 33 3 352 out of
lower control arm.
Attach special tool 33 3 354 between both control arms.

Press in new rubber mount (1) with special tools 33 3 351 and 33 3 353 .
After installation:
33 32 671 Replacing one rubber mount in the upper control arm (control arm
removed)

33 3 351
33 3 352
Press rubber mount with special tools 33 3 351 and 33 3 352 out of
upper control arm.
Place new rubber mount at chamfered end of control arm bore. Here,
longer collar (A = 17 mm) of rubber mount must point upwards.
Press in rubber mount with special tools 33 3 351 and 33 3 352 until flush.
After installation:
33 32 071 Replacing one upper control arm
Note:
If the upper control arm is detached from the rear axle carrier/trailing arm,
it is necessary after reinstallation to carry out a wheel/chassis alignment
check.
After installation:

Remove coil spring
Remove stabilizer link from upper control arm
If necessary, remove jointed rod of ride-height sensor from
upper control arm
If necessary, support rear differential and release bearing
screws on rear differential (output shafts do not have to be
removed)
Unfasten nut.
Remove screw towards rear.
Installation:
Observe bolt insertion direction (F = direction of travel).
Unfasten nut.
Remove screw towards rear.
Remove upper control arm at side.
Installation:
Observe bolt insertion direction (F = direction of travel).
33 33 515 Replacing two additional rubber mounts for rear axle carrier
(rubber mount at rear)

33 3 314
33 3 315
33 3 371
33 3 372
33 3 373
33 4 140
33 4 142
33 4 145
33 4 147
33 4 155
33 4 211
Warning!
Do not point air jet from hot air blower at fuel tank!

Lower rear axle carrier
Assemble special tool 33 4 140 with 33 4 142 and 33 4 147 / 33 4 211

(Compact).
Unscrew feed handle (1). If necessary, mount extension piece (3) on
special tool 33 4 145 with new screw (2).
Position special tools 33 4 140 , 33 4 155 , 33 3 371 , 33 3 372 and nut (1)
on openings of rubber mount.
Note:
Ensure it is correctly supported on bushing of rear axle carrier.
Using a hot air blower, heat bearing bushing at max. 600 °C outlet
temperature for approx. 2 minutes.
Pull out rubber mount by turning special tool 33 4 155 .
Coat rubber mount with Circolight anti-friction agent.Important!

When rubber mount is fitted, arrows (1) must point down longitudinal
axis of vehicle.
Draw in rubber mount with special tools 33 3 314 , 33 3 315 , 33 3 372 and
After installation:
Check seating of coil spring with spring pads, correct if necessary
33 33 101 Replacing two rubber mounts for rear axle carrier (rubber mounts,
front)

33 3 314
33 3 315
33 3 371
33 3 372
33 3 373
33 4 140
33 4 142
33 4 145
33 4 147
33 4 155
33 4 211
Warning!
Do not point air jet from hot air blower at fuel tank!

Lower rear axle carrier
Assemble special tool 33 4 140 with 33 4 142 and 33 4 147 / 33 4 211

(Compact).
Unscrew feed handle (1). If necessary, mount extension piece (3) on
special tool 33 4 145 with new screw (2).
Position special tools 33 4 140 , 33 4 155 , 33 3 371 , 33 3 372 and nut (1)
on openings of rubber mount.
Note:
Ensure it is correctly supported on bushing of rear axle carrier.
Using a hot air blower, heat bearing bushing at max. 600 °C outlet
temperature for approx. 2 minutes.
Pull out rubber mount by turning special tool 33 4 155 .
Coat rubber mount with Circolight anti-friction agent.Important!

Front rubber mounts differ:
Rubber mount VR = front right with elongated hole (1)
Rubber mount VL = front left
When rubber mount is fitted, arrows (2) must point down longitudinal
axis of vehicle.
Draw in rubber mount with special tools 33 3 314 , 33 3 315 , 33 3 372 and
After installation:
Check seating of coil spring with spring pads, correct if necessary
33 41 ... Detaching wheel bearing inner race from drive flange (drive flange
removed)

33 1 307
33 4 400
33 4 401
33 4 402
33 4 403
33 4 404
33 4 405
33 4 406
33 4 407
Note:
Detach wheel bearing ring with special tool 33 4 400 through groove in
wheel bearing inner ring.
Position special tool 33 1 307 on drive flange.

Select one of the following special tools using the wheel bearing inner
ring and insert into special tool 33 4 401 .
33 4 405 for dia. 45 - 51 mm
33 4 406 for dia 50 - 55 mm
33 4 407 for dia. 55 - 61 mm
Screw out special tool 33 4 402 until the tapered attachment of the
spindle comes into contact with the special tool33 4 401 .
Position special tool 33 4 401 with the corresponding insert on groove of
wheel bearing inner ring.
Compress special tool 33 4 401 with wrenches 33 4 403 and33 4 404 until
the special tool can still be turned in the groove.
Detach wheel bearing inner ring by turning special tool 33 4 402 .
33 41 000 Replacing drive flange on left/right rear axle shaft

33 2 116
33 2 160
33 2 201
33 4 041
33 4 042
33 4 043
33 4 045
33 4 048
33 4 200
Apply handbrake.
Remove rear wheel.
Unscrew collar nut.
Installation:
Replace collar nut, apply a light coating of oil to contact surface and
tighten down.
Remove output shaft.

Remove brake disk.
Remove pulse generator.

Important!
Force drive flange with special tools 33 2 116 / 33 2 201 , 33 2 160 ,

33 4 200 and five wheel bolts out of wheel bearing.Note:
Important!
The wheel bearing is destroyed when the drive flange is removed
and cannot be reused!
Replace wheel bearing.
Installation:
Draw in drive flange with special tools 33 4 041 , 33 4 042 , 33 4 048 ,
33 4 045 and 33 4 043 .
After installation:
Adjusting handbrake
33 41 151 Replacing wheel bearing (75 mm) on rear axle shaft on left or right

33 4 031
33 4 041
33 4 042
33 4 043
33 4 047
33 4 048
33 4 049

Remove drive flange of rear axle shaft
Detach wheel bearing inner race from drive flange.
Press retaining ring (1) together using pliers and remove.Installation:

Check seating of retaining ring (1), correct if necessary.
Pull out wheel bearing with special tools 33 4 041 , 33 4 042 , 33 4 031 ,
33 4 048 and 33 4 043 .
Important!
Do not reuse old wheel bearing!
Note installation direction of wheel bearing.
Red sealing ring must point outwards!
Installation:
Draw in new wheel bearing (1) with special tools 33 4 041 , 33 4 042 ,
33 4 049 , 33 4 047 and 33 4 043 .
After installation:
Adjusting handbrake
33 41 151 Replacing wheel bearing (85 mm) on rear axle shaft on left or right

33 3 261
33 3 262
33 3 263
33 3 264
33 3 265

Remove drive flange of rear axle shaft
Detach wheel bearing inner race from drive flange
Press retaining ring (1) together using pliers and remove.Installation:

Check seating of retaining ring (1), correct if necessary.
Pull out wheel bearing with special tools 33 3 261 , 33 3 262 and 33 3 263
.
Important!
Do not reuse old wheel bearing!
Note installation direction of wheel bearing.
Red sealing ring must point outwards!
Installation:
Draw in wheel bearing (1) with special tools 33 3 261 , 33 3 264 and
33 3 265 .
After installation:
Adjust handbrake
Situation:
E32, E34, E38, E39: With the rear spring struts with self-levelling suspension, a slight oil leak usually exists at
the piston rod. These spring struts are permitted to be wet with oil over a maximum of half the shock absorber
length on the outer tube, i.e. they are permitted to ”sweat”.
Effect:
Procedure:
Parts Department)
33 52 000 Removing and installing/replacing rear left or right shock absorber
Installation note:
must be replaced.
must be replaced.
Note:
Read and comply with Information on replacing shock absorbers.

Remove rear wheel
Removing luggage compartment trim panel
Warning!
Danger of injury!
persons.

platform
Support trailing arm with a workshop jack (1).

Release screw.
Installation note:
Thrust washer (2) on rubber mount must point to screw head.
Tighten bolt in normal position.
Unscrew nuts.
Remove reinforcement plate if necessary.
Remove shock absorber with support bearing downwards.
Installation note:
Note:
If a reinforcement plate (1) was installed on the left side of the vehicle,
this must be re-installed and both support bearings must also be sealed
with butyl tape (2).
Replacement:
Remove support bearing.
Remove or pull off disc (1), shim, auxiliary absorber (2) with protective
tube (3) from shock absorber (4).
Installation note:
Check auxiliary absorber (2) and protective tube (3) for damage, replace
if necessary.
After installation:
33 52 161 Replacing rear left or right thrust bearing for spring strut/shock
absorber
Installation note:
must be replaced.
must be replaced.

Remove rear shock absorber
Slacken nut (1).

Remove disc (2) and support bearing (3).
Installation note:
33 53 ... Measuring ride-level height of vehicle

Determine actual ride height (A) - to do so, attach tape measure to rim
flange (2) at bottom middle and measure to lower edge of wheel arch (1).
33 53 000 Removing and installing / replacing rear left or right coil spring
Important!
Except M model: Both coil springs on the relevant axle must be
replaced in the event of corrosion breakage.
M model: For safety reasons, both coil springs on the relevant axle
must always be replaced on motorsport vehicles!
The spring pads at the top and bottom must also be renewed when
replacing the coil springs.
Note:
The coil spring is allocated in the Electronic Parts Catalogue (EPC) under
the item "Spring table" after the vehicle identification number has been
entered and the optional equipments of the car have been selected.
Installation note:
must be replaced.
must be replaced.

Remove rear wheel.
Remove output shaft from rear axle final drive and tie back.
Remove anti-roll bar on relevant side from rear axle support
If necessary, remove jointed rod from sensor lever of ride
height sensor.
Detach panel from fuel tank (in rear area).

Important!
Brake hose must not be exposed to tensile loads!
Release screw and remove holder with brake hose.

Warning!
Danger of injury!
persons.
When supporting components, make sure that:

platform
Support trailing arm with a workshop jack (1).

Release screw.
Lower workshop jack (1).
Installation note:
Thrust washer (2) on rubber mount must point to screw head.
Tighten down screw in normal position.
Press trailing arm downwards.

Pull out coil spring to the side.
Remove upper spring pad (1) from take-up locator/frame side member.
Installation note:
Position coil spring with upper spring pad (1) on lower spring pad (2)
mounted in wishbone and align to take-up locator/frame side member.
Raise trailing arm using a workshop jack.
Important!
Spring pads must be positively seated in the take-up locator/frame
side member or wishbone to prevent the coil spring from springing
out of the centring mount.
Note:
Equipment specification with bad-road package: upper spring pad is
14.5 mm thick.
Installation note:
Check spring pads (1, 3) for damage, replace if necessary.
Attach top spring pad (1) to coil spring (2).
After installation:
33 55 000 Removing and installing / replacing rear stabilizer
Remove stabilizer bar from top control arm and from rear axle carrier. If
necessary, remove stabilizer links,
refer to 33 55 040.
Installation:
Stablizer bar and rubber mount free of grease. Coat retaining
bracket with Circolight, refer to BMW Parts Service.
33 55 000 Removing and installing / replacing rear stabilizer bar
Remove spare wheel (1) from spare wheel recess.

Release screw (2).
Release screws (1) and remove spare wheel recessÂ (2).
Release screws (1) on bearing pedestal stabilizer link.
Release screws (1).

Remove stabilizer bar with rubber mounts from control arm at top and
from rear axle carrier.
Note:
For installation and removal, remove bearing pedestal if necessary.
Installation:
Stabilizer bar and rubber mount free of grease. Coat retaining
bracket with Circolight, refer to BMW Parts Service.

Feed out stabilizer bar over lowered rear muffler (2).
33 55 040 Replacing anti-roll bar links for anti-roll bar
Remove anti-roll bar

refer to 33 55 000.
Clamp anti-roll bar link in vice with protective jaws and remove anti-roll bar
using rotary movements.
If the rubber mount remains on the anti-roll bar, cut through with knife and
remove.
Clamp new stabilizer link in vice with protective vice jaws.

Moisten end of anti-roll bar and inside of rubber mount with Circolight
mounting agent (refer to BMW Parts Service).
Press stabilizer as far as possible into stabilizer link with rotary motions.
Immediately rotate stabilizer link into illustrated angular position to

stabilizer. Once mounting agent has evaporated, stabilizer link can no
longer be rotated.
33 55 040 Replacing anti-roll bar links for stabilizer bar
Remove anti-roll bar

refer to 33 55 000.
Clamp anti-roll bar link in vice with protective jaws and remove anti-roll bar
using rotary movements.
If the rubber mount remains on the anti-roll bar, cut through with knife and
remove.
Clamp new stabilizer link in vice with protective vice jaws.

Moisten end of anti-roll bar and inside of rubber mount with Circolight
mounting agent (refer to BMW Parts Service).
Press stabilizer as far as possible into stabilizer link with rotary motions.
Immediately rotate stabilizer link into illustrated angular position to

stabilizer. Once mounting agent has evaporated, stabilizer link can no
longer be rotated.
33 55 021 Replacing both rubber mounts for stabilizer mounting
Release nuts (1) on both sides.

Turn stabilizer in downwards direction.
Remove retaining bracket (2) on both sides.
Remove rubber mount (3) on both sides.
Installation:
Keep retaining bracket (2), rubber mount (3) and stabilizer if necessary
clean and free from oil and grease.
Version with Dynamic Drive: Keep contact face for rubber mount on anti-
friction bearing clean and free from oil and grease.

temperature.
Installation note:
curing)
34 00 048 Bleeding brake system with ABS/ASC+T
Note:
Note "General Data",
refer to 34 00 ...
Connect BMW Diagnosis and Information System (DIS).

Call up service function Bleeding ABS/ASC+T Hydraulics.
Connect bleeding unit to expansion tank and switch on.
Note:
Check relevant operating instructions for each device.
Charging pressure must not exceed 2 bar.
Flush braking system completely.

Connect bleeder hose and bottle to bleed valve on rear right brake
caliper.
Open bleed valve and flush until clear, bubble-free brake fluid emerges.
Close bleeder valve.
Follow same procedure on rear left, front right and front left wheel brake.
Bleed rear-axle brake circuit.

To bleed the rear wheel brake, follow the procedure specified in the DIS
(Diagnosis Information System).
Bleed front-axle brake circuit.
Connect bleeder hose and bottle to bleed valve on front right brake
caliper.
Open bleed valve.
Fully depress brake pedal at least 12 times. Brake fluid must emerge
clear and free of bubbles.
Hold down brake pedal in fully depressed position.
Release brake pedal.
Follow same procedure on front left wheel brake.
Switch off bleeder unit and remove from expansion tank.

Check brake fluid level.
Close expansion tank.
Note:
Take care of rubber gasket (1) in lid.
34 00 050 Bleeding brake system with DSC3
Note:
Read and comply with General Information.
When replacing or repairing, observe the filling and bleeding instructions
for the following parts:
1. Brake master cylinder
2. Hydraulic unit DSC3
3. and components/connecting lines which are fitted between these
assemblies.
For all other work on the brake system (e.g. replacing brake calipers), the
instructions ”Bleeding brake system with ABS/ASC+T” must be observed.
34 00 048
After work has been completed on the precharging pump, only the front
axle circuit has to be bled. Activate precharging pump once with
Diagnosis and Information System (DIS).
(Brake fluid changer connected to max. 2 bar filling pressure).
After completing work: Carry out final check with DIS under menu item
”Service functions”.
Contrary to the instructions in the DIS, the bleeding routine must be
restarted on each wheel.
Always use BMW-approved brake fluids, refer to BMW Operating Fluids.
Connect DIS.
Call up service function ”Bleeding ABS/DSC3 Hydraulics”.
Connect brake fluid changer to expansion tank and switch on.
Note:
Check relevant Operating Instructions for each device.
Fully rinse the brake system

Connect bleeder hose with collecting tray to bleeder valve on rear right
brake calliper.
Open bleeder valve and purge until clear, bubble-free brake fluid
emerges.
Close bleed valve.
Follow same procedure on wheel brakes rear left, front right and front left.
Bleeding rear-axle brake circuit
brake calliper.
Run bleeding routine with DIS with bleeder valve open.
After completing the routine, press brake pedal 5 times down to floor;
clear bubble-free brake fluid must emerge.
Close bleed valve.
Repeat procedure at rear left.
Bleeding front-axle brake circuit

Connect bleeder hose with collecting tray to bleeder valve on front right
brake caliper.
Run bleeding routine with DIS with bleeder valve open.
After completing the routine, press brake pedal 5 times down to floor;
clear bubble-free brake fluid must emerge.
Close bleed valve.
Repeat procedure at front left.
Switch off brake fluid changer and remove from expansion tank.
Note:
Take care of rubber gasket (1) in lid.
34 00 009 Checking brakes on test stand
Note:
1. Check tires for damage
2. Check tire treads
3. Check tire pressures
In the case of vehicles with ASC+T or DSC, the system must be

deactivated with the switch. The ASC+T / DSC indicator lamp in the
instrument cluster must light up!
The brakes must be at normal operating temperature. For this purpose,
gently warm up the brake disks/drums while dry by braking the vehicle
several times.
Caution!
You should only use brake dynamometers whose test speed is
≤ 5 km/h.
You must follow without fail the guidelines contained in the
operating instructions of the relevant test stand manufacturer.
Failure to do so may result in damage to the vehicle and the
system and also personal injury.
The maximum test duration for four-wheel drive vehicles is 3
minutes per axle! If it has to be repeated, it will be necessary in the
meantime to the drive the vehicle a distance of at least 1 km in
order to achieve sufficient lubrication of the transfer case.
34 00 513 Checking parking brake setting (for inspection)
Note:
If deviations are identified during the following check, the parking
brake must be adjusted:
E46: refer to 34 10 014
E39, E52 and E53: refer to 34 10 014
E38: refer to 34 41 006
E46/E39/E53/E52
Release handbrake lever; it must be possible to turn wheels easily.
Switch ignition on; indicator light must not be on when handbrake lever is
released.
1st tooth: No braking effect, but indicator lamp can be lit.
2nd tooth: Braking effect must begin, indicator lamp must light up.
E38
Release handbrake lever; it must be possible to turn wheels easily.
Switch ignition off; indicator light must go off when handbrake lever is
released.
1st tooth: No braking effect, but indicator lamp can be lit.
2nd tooth: Braking effect can begin, indicator lamp must light up.
3rd tooth: Braking effect must begin, indicator lamp must light up.
34 00 519 Checking service brake: high- and low-pressure tests
Important!
The high/low-pressure test (leakage test) must be carried out with
the engine switched off.
High-pressure test (leakage test):

Perform test on both brake circuits.
1st brake circuit, front axle
2nd brake circuit, rear axle
Remove bleeder screw, connect pressure tester and bleed.
Load brake pedal with a force and block brake pedal with pedal support,
After 2 minutes, pressure is permitted to drop by max. 8 %.
Low-pressure test:
Perform test on both brake circuits.
Reset pedal support until test pressure in braking system is 2 ... 5 bar.
Vehicle and measuring apparatus must remain steady as vibrations will
distort the result.
Pressure must remain constant for a test period of 5 minutes.
Check all rubber parts in case of excessive pressure drop.
Bleed brake calipers and wheel brake cylinders after finishing test.
34 00 010 Checking thickness of brake lining

34 1 260
Note:
The thickness of the outer brake linings can be determined without
removing the wheels.
If necessary, move car until opening for brake lining wear indicator
(brake lining) can be seen through rim styling.
E38:
This check can be carried out from model year 97.
E52:
This check is only possible on the rear brakes. To check front brake
linings: remove both front wheels.
Insert special tool 34 1 260 through rim into opening for brake lining wear
indicator.
Press special tool onto brake lining. Slide ring (1) in direction of arrow as
far as it will go and read off measured value.
Note:
(A) Brake disk
(B) Brake lining with backplate
Residual lining thickness of front wheel brake:
Residual lining thickness of rear wheel brake:
34 00 ... General Data
The brake system is one of the most important safety systems on any motor vehicle. It is therefore essential
to act with utmost care when working on the brake system and to follow the instructions below.
- Ensure cleanliness and only use rags which do not lose lint.
- Wash away or vacuum up brake dust: do not clear it away using compressed air. This dust is a health
hazard.
- Ensure that no oils or grease enter the brake system: these substances would cause complete failure of
the entire brake system.
- When cleaning brake components with brake cleaning fluid (refer to BMW Parts Service), no brake cleaning
fluid must enter the brake system.
- Even the most minute traces of brake cleaning fluid must be avoided.
- Replace brake fluid at least every two years.
- Never re-use drained brake fluid.
- Always use BMW-approved brake fluid, refer to BMW Service Operating Fluids.
- Always dispose of brake fluid in approved receptacles, refer to BMW Service Workshop Planning
documentation.
- Do not allow brake fluid to drain into drain pipes, into the outside environment or into unsuitable facilities.
This would create the risk of groundwater contamination since brake fluid is classed as a fluid that is
hazardous to water.
- Do not allow brake fluid to come into contact with paintwork as this will destroy the paint.
- Brake fluid must not be allowed to remain on bare skin too long in order to avoid skin problems. Wash skin
coated with brake fluid with water and soap.
- If brake fluid makes contact with eyes, immediately flush with large quantity of clean water and visit eye
doctor.
- Brake linings:
Brake linings should be replaced when the warning threshold of the brake lining wear indicator is replaced.
Brake linings must always be replaced on both sides of any axle.
The friction faces of brake linings must not come into contact with oils or grease and if brake linings become
contaminated with substances of this kind, they must be replaced.
In the case of rotation-dependent brake linings, make sure the arrow marking points in the direction of
rotation of the brake disk for when the vehicle is moving forward. Brake linings with left/right markings must
be installed on the respective vehicle side.
One-sided angled areas on the brake linings must be located on the disk contact side of the brake caliper
for when the vehicle is moving forward.
- Brake discs:
Brake disks must not be scored or cracked; in addition, the minimum disk thickness, disk run-out, parallelism
and surface roughness of the friction surfaces must not exceed or drop below the permitted values.
Always strip preservative off new parts before installation. With the rear brake discs, also strip preservative
off brake drum on parking brake.
- Brake drums:
Brake drums must not be scored or cracked; in addition, the maximum drum diameter, radial runout and
surface roughness of the friction surfaces must not exceed or drop below the permitted values.
Always strip preservative off new parts before installation.
- Brake calipers:
Only approved pastes on the basis of glycine must be used for repairs of brake calipers.
All moving parts on the brake caliper must move freely: note grease specifications.
To grease the caliper guides, always use BMW-approved lubricants (refer to BMW Service Operating
Fluids).
- Brake lines and brake hoses must be correctly routed and must not abut with body or components in a way
which would cause chafing.
- To prevent damage, release and tighten brake line couplings with a special brake line wrench only.
- The system must be bled each time any brake lines have been detached.
- Check all connection points for leaks (seal integrity).
- Only tighten down brake hoses on the front axle when wheels are in straight-ahead position.
- Close open connections on brake lines and individual components to prevent dirt from entering the brake
system.
- Observe tightening torques when tightening down brake line couplings,
refer to tightening torques 34 32 1AZ.
The ABS is essentially maintenance-free but bear in mind the following when working on vehicles with ABS
systems:
- When carrying out welding work with electric welding equipment, be sure to disconnect the plug from the
electronic control unit (ignition turned off).
- During painting work, the electronic control unit may be subjected for brief periods to loads of max. 95°C
and for long periods (approx. 2 hours) to loads of max. 85°C.
- Terminals must be completely tight on end poles of battery.
- Brake lines on hydraulic unit must not be swapped over: if applicable, mark them prior to disassembly.
- The ABS must be tested in accordance with the ”Electrical Troubleshooting Manual” if one of the following
ABS components has been removed or replaced:
- Hydraulic control unit

- ABS control unit
- Wheel-speed sensor
- ABS wiring harness
- Valve control relay
- Relay pump motor
In vehicles with ASC+T, the ABS/ASC control unit must be readjusted if one of the following components
has been removed or replaced:
- ABS/ASC+T control unit

- Throttle-valve assembly
- Throttle potentiometer
34 00 ... General information on braking in new brake discs / brake pads
Important!
After completing work:
Carry out function check on brake test stand to ensure that
the brakes complies with legal requirements.
Carry out test braking while driving at low speed; the
effectiveness of the brakes may be reduced during the initial
braking operations.
Exaggerated drastic and continuous braking operations for
faster braking in are not permitted.
Advise the customer not to perform any wilful drastic braking in
the first 200Â km after brake replacement.
Attach mirror tag to interior rearview mirror.
34 00 x01 Guideline for applying brake pad paste on brake pads and caliper
carrier
Attention!
So as not to damage the surface coating, if possible do not
mechanically clean the guide surfaces for the brake pads on the
brake caliper mounting bracket, but rather clean with brake
cleaner BMW TI. Clean number 83 19 2 154 780 and apply a thin
coating of BMW TI break pad paste. Coat number 83 19 2 158 851
(3 gr.) or 83 19 2 158 852 (100 gr.).
Spread brake pad paste onto the marked surfaces using a brush!
(1) Brake pad paste 100 gr. BMW Tl. Number 83 19 2 158 852
(3) Brush for spreading brake pad paste over the marked areas.
Attention!
If new brake pads are mounted on a brake disc, the following
must be observed:
Bevel edges in the area (1) slightly (dimension A must not
exceed maximum 1 mm).
These procedures applies for all the following described brake systems.
IPS brake (made by CBI), 1-piston floating caliper brake (model

ranges: 1-Series, 3-Series, 4-Series, X3)
Clean contact surface (1) of brake piston with brake cleaner and apply a
thin coating of brake pad paste.
Clean contact surfaces (1) of T-heads/brake calliper housing with brake
cleaner and apply a thin coating of brake pad paste.
Clean contact surface (1) of brake caliper with brake cleaner and apply a
So as not to damage the surface coating, if possible do not mechanically

clean the guide surfaces (1) for the brake pads on the brake caliper
mounting bracket. Clean guide surfaces (1 and 2) with brake cleaner and
apply a thin coating of brake pad paste.

clean the guide surfaces (1 and 2) for the brake pads on the brake
calliper mounting bracket. Clean guide surfaces (1 and 2) with brake
Apply a thin coating of brake pad paste to T-head of inner brake pad in
area (1) and (2).
Apply a thin coating of brake pad paste to T-head of outer brake pad in
area (1) and (2).
FN brake (made by Continental Teves), 1-piston floating caliper brake

(model ranges: 5-Series, 6-Series, 7-Series, 8-Series, X1, X3, X5, Z4,
Rolls-Royce)


mounting bracket. Clean guide surfaces (1) with brake cleaner and apply
a thin coating of brake pad paste.

Lightly coat the T-head of the inner brake pad with brake pad paste in
area (1 and 2).
Lightly coat the T-head of the outer brake pad with brake pad paste in
area (1 and 2).

(model ranges: 5-Series, 6-Series, 7-Series, 8-Series, X5, Rolls-Royce)

Clean contact surface (1) and brake caliper with brake cleaner and apply

area (1 and 2).
area (1 and 2).
Collette brake (made by TRW), 1-piston brake caliper (model ranges:

MINI, 1-Series, 5-Series, 6-Series, Z4)

clean the guide surface (1) for the brake pads on the brake caliper
mounting bracket. Clean guide surface (1) with brake cleaner and apply a
Apply a thin coating of brake pad paste to both sides of T-head of brake
pad in area (1).
P 4.40 brake (made by Brembo), 4-piston fixed caliper brake (model

ranges: MINI, 1-Series, 3-Series, 4-Series, 5-Series, 6-Series, 7-Series,
8-Series, X5, Rolls-Royce)
clean the guide surfaces (2) for the brake pads on the brake calliper
Clean both inner and outer guide surfaces (2) and apply a thin coating of
brake pad paste.
Lightly coat both sides of the contact surface in area (1 and 2) with brake
pad paste.
Lightly coat the brake pad contact surface on both sides in area (1) with
brake pad paste.

ranges: 1 Series, 2 Series, 3 Series; does not apply to M2 F87)
brake pad paste.
pad paste.
brake pad paste.
Brake (made by Brembo), 4-piston fixed caliper brake (model ranges:

MINI F5x sport brake)
Check dust boot (1) for damage and replace if necessary.

Clean brake caliper compartments (2) and apply a thin coating of brake
pad paste.
brake pad paste.
Do not grease the brake lining backplate and thoroughly clean it with
brake cleaner!
Only use new claw plates!
Slightly raise the protective film (1) at a place.
Insert the claw plates (1) into the brake pistons.
Pull off the protective film (1) with long-nose pliers (2).Attention!
The bonding surface of the claw plates must not be touched!
Install the brake caliper (1) in direction of arrow.

Parts: Replace screws (2).
Insert screws (2) and tighten.
Install the brake pad (1).Attention!
The brake pads must not touch the bonding surface of the claw
plates when inserting!
Apply the brake pads to the brake disc and insert.
In order to ensure a complete bonding of the claw plates with the

brake pads, the following instruction must be strictly adhered to:
Strongly press the brake pedal and hold it for at least 1 min!
Brake (made by Continental), 4-piston fixed caliper brake (model

ranges: 7-Series (G11, G12)
Clean the contact surface (1) of the brake piston (4 pieces) with brake
cleaner.
Check the dust boots (2) and renew as necessary.
Always renew retaining plates 1!

Mount retaining plate 1.
It is paramount that the slide panels are correctly positioned in the
guides!
clean the guide surfaces for the brake pads on the brake caliper
mounting bracket.
Apply a thin layer of brake pad paste to the surfaces of the sliding plates
(1).

7-Series (G11, G12)
cleaner.
Adhesive residues must be completely removed.
To prevent damage to the surface coating, do not clean the guide

surfaces (1) for the brake pads on the brake calliper mechanically, if
possible.
Clean guide surfaces (1) with brake cleaner and apply a thin coating of
brake pad paste.
Remove the protective film of the adhesive layer (1) from the brake
pads.
Do not touch the adhesive layer!
Insert brake pads in the brake caliper, making sure the adhesive layer
does not touch the brake pistons.
Fit retaining clip (1).
Drive in the locking pins (2) in the direction of the arrow.
Attention!
After the brake pads have been installed they must immediately be
bonded to the brake pistons:
Step on the brake pedal to the floor and hold the pressure for
one minute. This causes the brake pads to adhere to the
brake pistons.
34 00 012 Parking brake function check
Note:
If deviations are identified during the following check, the parking
brake must be adjusted:
Drive vehicle onto chassis dynamometer.

Warm up brakes.
Check handbrake.
0th tooth
(handbrake Vehicles with manual transmission: Shift lever in
released): neutral position.
Vehicles with automatic transmission: Selector
lever in ”N” position.
Without locking differential ≤150 N.
With locking differential ≤ 200 N (possibly
odd display).
1st tooth: No increase in braking force with regard to

0th tooth. Indicator lamp can be lit.
2nd tooth: Indicator lamp must be lit.
3rd tooth: Increase in braking force.
5th tooth: The brake force display must have reached ≥
400 N.
Checking brake force differential at wheel:
Apply handbrake until a wheel circumferential force (measured on brake
test stand) of min. 1000 N is reached.
Max. permitted brake force differential right/left ≤35 % (referred to greater
brake value).
It must be possible to brake with locked wheels with the handbrake.
34 00 025 Replacing fluid in ABS/ASC+T brake system
Note:
The capacities are oil change quantities. See Electronics Parts
Catalogue/Commercial Service Data (ETK/KSD) (capacities)
Important!
When carrying out repair work to the brake system, follow the
procedure set out in Bleeding brake system.
Connect brake fluid changer to expansion tank and switch on.

Note:
Check relevant equipment manufacturer's operating instructions for
each device.
Only use brake fluids that have been approved by BMW, see BMW
Service Operating Fluids.
Fully rinse the brake system

brake caliper.
Open bleeder valve and purge until clear, bubble-free brake fluid
emerges.
Close vent valve.
Follow same procedure on rear left, front right and front left wheel brake.
The clutch slave cylinder must also be scavenged in vehicles with

manual transmissions.
Switch off brake fluid changer and remove from expansion tank.
Note:
Pay attention to rubber seal (1) in sealing cap.
34 11 ... Configuration of floating caliper (front)
1 Brake-caliper housing 7 Guide bolt

2 Brake console 8 Protecting plug
3 Spring retainer 9 Brake-pad-wear sensor
4 Bolt 10 Brake caliper gasket set
5 Bleeder valve 11 Guide-sleeve repair kit
6 Dust cap 12 Brake linings repair set
34 11 552 Overhauling left or right front brake caliper (brake caliper
removed)

00 9 316
Note:
Use repair kit,
Warning!
Risk of injury!
In the following work step, large forces occur at the brake calliper
piston (up to more than
2800 N).
Important!
Do not grip piston with fingers - risk of trapping!
To protect piston, place a protective plate (e.g. hard wood or hard
felt) in calliper recess.
Carefully force piston out through connection bore with compressed air.
Check guide sleeves (5), fitting repair-kit guide sleeve if necessary.

Press off dust sleeve (1).
Carefully remove seal (1) with special tool 00 9 316 .

Clean cylinder bores and parts with alcohol and dry with compressed air.
Thoroughly inspect cylinder bore, piston and flange surfaces. Machining
of cylinders and pistons is not permitted.
Install new seal.
Installation:
Apply a light coat of Ate brake cylinder paste to cylinder bore, piston and
seal,
Fit dust sleeve (1) in annular groove of piston (2).

Important!
Do not tilt piston.
Press piston into cylinder bore.

Evenly press dust sleeve onto brake calliper housing as far as it will go.
Installation:
The area between the dust sleeve and the brake calliper housing must
be kept dry. It must not come into contact with Ate brake cylinder paste
or brake fluid so as to ensure that the dust sleeve is perfectly seated.
34 11 552 Overhauling left or right front-brake caliper (brake caliper
removed)
Note:
Use repair kit,
Take off plastic caps (1).

Unscrew guide bolts (2).
Installation:
Only clean guide screws; do not grease. Check guide bolts, replace
if necessary.
Dismantle brake caliper and remove brake linings.Installation:

Press brake lining fully outwards and insert spring (4).
Warning!
In the following work step, large forces occur at the brake caliper
piston (up to more than
2800 N!).
Danger of injury!
Press out piston with compressed air applied through connection bore.
To protect piston, place a protective plate (e.g. hard wood or hard felt) in
caliper recess.
Remove sealing ring carefully with a plastic needle.

Installation:
Apply a light coat of Ate brake cylinder paste to cylinder bore, piston
and sealing sleeve,
Install sealing cover in rear annular groove of cylinder bore.
Insert dust sleeve in front annular groove and press into annular groove
over entire diameter.Installation:
Area between dust sleeve and brake caliper housing must be kept
dry. It must not come into contact with Ate brake cylinder paste or
brake fluid so as to ensure that the dust sleeve is perfectly seated.
Support brake piston with commercially available extension and socket
and press gently onto dust sleeve.
Blow on sleeve with compressed air (max. 3 bar). Sleeve jumps over
brake piston.
Installation:
Coat dust sleeve and brake piston with brake fluid to facilitate
installation of dust sleeve.
34 11 667 Precision-turning both front brake discs on both sides (brake disc
removed)
Important!
Always precision-turn both sides of both brake discs on one axle.
Observe max. machining dimension per friction ring side,
minimum brake disc thickness (MIN TH)
and surface roughness of brake surfaces.
Brake discs of M models (Compound brake discs) must not be
machined!
Note:
On brake discs that have been ground down to the minimum brake
disc thickness (MIN TH),
see Technical data,
only one more brake pad set may be used.
Processing equipment, see BMW Service Workshop Equipment -

Planning Documentation.
Follow the equipment manufacturer's operating instructions.
34 11 250 Removing and installing/replacing a front brake anchor
plate/brake guard plate
Remove wheel hub (1).

Release screws (2) and remove brake guard plate (3).
34 11 220 Removing and installing/replacing both front brake discs

34 1 280

Remove wheels .
If necessary, remove and clean brake pads .
Check minimum brake disc thickness:

Position special tool 34 1 280 at three measuring points in area (1)
and measure.
Compare measurement result and lowest value with setpoint value
.
Brake discs may only be replaced in pairs (for each axle).
If the brake discs are replaced, you must also fit new brake pads.
The brake discs of M models are tied to the direction of travel:
The uneven part number denotes the left brake disc, the even part
number the right brake disc!
Important!
New brake pads may only be fitted if the brake disc thickness is
greater than the minimum brake disc thickness (MIN TH).
Release screws (1), remove brake caliper and tie up.Note:

Brake hose remains connected.
Installation:
Unscrew bolts and take off brake disc.
Important:
To release brake disc: Do not under any circumstances strike friction ring
with a hammer or similar! If necessary, carefully tap on base of brake disc
chamber with a rubber mallet.
Installation:
Replace brake disc retaining screw.
Thoroughly clean contact surface of wheel hub, remove traces of
corrosion if necessary.
Unevenness on contact surface may result in distortion of brake
disc!
Important!
Internally ventilated brake discs are balanced.
Never remove or reposition balance clips.
34 11 000 Removing and installing/replacing brake pads of both front disc
brakes

34 1 050
34 1 280
Note:
When the repair work is finished, press the brake pedal a few times
so that the brake pads fit closely against the brake discs.
When installing new brake pads on the front axle with simultaneous
renewal of brake pads on the rear axle, check the brake fluid level, if
required top up to the "MAX" mark.
Remove wheels,
Important!
Brake pad wear sensor: after removal it must be replaced
(brake pad wear sensor loses its retention capability in the
break pad).
Retaining pins and expanding spring: for vehicles older
than 48 months it is recommended to replace the retaining
spring!
brake caliper mounting bracket. Instead, clean with brake cleaner
BMW part no. 83 19 2 154 780 and apply a thin coating of brake
pad paste BMW part no. 83 19 2 158 851 (3 g) or 83 19 2 158 852
(100 g).
Observe guideline for applying brake pad paste on brake pads
and brake anchor plate !
Lift out retaining spring (1).

Left:
Disconnect plug connection for brake pad wear sensor.
If necessary, replace brake pad wear sensor.
Remove plastic plugs (2).
Unfasten guide bolts (1) and lift out brake caliper towards rear of vehicle.
Do not allow brake caliper to hang from brake hose, risk of damage to
brake hose.
Installation note:
Only clean guide screws; do not grease.
Check threads.
Replace all guide screws which are not in perfect condition.
Turn piston back fully with special tool 34 1 050 .Important!

When turning back the piston, watch the brake-fluid level in the
expansion tank, as overflowing brake fluid will destroy the paintwork.
Remove outer brake pad.

Inner brake pad is located with its spring in the piston.
Important!
Mark any worn brake pads.
In the event of one-sided brake pad wear, do not change brake pads
round.
Observe minimum thickness of brake pads.
Clean brake pads.
Do not apply grease to brake lining backplate.
and measure.
Compare measuring result and lowest value with setpoint value.
Important!
New brake pads may only be installed if the brake disc thickness is
greater than or equal to the minimum brake disc thickness (MIN TH)
(not incl. M vehicles).
In the case of M vehicles and perforated brake discs, new brake
pads may only be installed if the brake disc thickness is greater than
the minimum brake disc thickness (MIN TH).
Note:
The minimum brake disc thickness is configured in such a way that it lasts
the life of a further set of brake pads (does not apply to M vehicles and
perforated brake discs).

Important!
Dust boot must not come into contact with anti‐squeak compound
as this may cause the dust boot to swell.
Clean contact surfaces (1) of T-heads/brake caliper housing with brake



clean the guide surfaces (1 and 2) for the brake pads on the brake caliper
area (1 and 2).
area (1 and 2).
34 11 519 Removing and installing/replacing left or right front brake caliper
Remove wheels. Note:

After completing tasks, bleed brake system.
Apply pedal prop and depress brake pedal slightly. This prevents brake
fluid from emerging from the expansion tank and air from entering the
brake system after the brake lines have been detached.
Disconnect brake pipe from connection with brake hose.
Left:
Remove connector for wear indicator.
Installation:
Tighten brake hose on brake caliper.
Set steering to straight-ahead setting.
Screw brake hose to brake line, ensuring that brake hose is not
twisted.
Unscrew bolts (1) and remove brake caliper.Installation:

34 21 947 Fine-grinding both sides of both rear brake disks (brake disks
removed)
Important!
Always fine-grind both sides of both brake disks on one axle.
Note MAX. machining dimension per friction ring side,
minimum brake disk thickness (MIN TH) and
Observe surface roughness of brake surfaces.
Only one brake lining set may be used up on brake disks which
have been lathe-turned to minimum thickness (MIN TH).
Brake disks of M models (Compound brake disks) must not be
machined!
Grinding machine: refer to BMW Service

Workshop Equipment/Planning documentation.
Follow the machine manufacturer's operating instructions.
34 00 x01 Guideline for applying brake pad paste on brake pads and caliper
carrier
Attention!
brake caliper mounting bracket, but rather clean with brake
cleaner BMW TI. Clean number 83 19 2 154 780 and apply a thin
coating of BMW TI break pad paste. Coat number 83 19 2 158 851
(3 gr.) or 83 19 2 158 852 (100 gr.).
(3) Brush for spreading brake pad paste over the marked areas.
Attention!
If new brake pads are mounted on a brake disc, the following
must be observed:
Bevel edges in the area (1) slightly (dimension A must not
exceed maximum 1 mm).
These procedures applies for all the following described brake systems.
IPS brake (made by CBI), 1-piston floating caliper brake (model

ranges: 1-Series, 3-Series, 4-Series, X3)


Apply a thin coating of brake pad paste to T-head of inner brake pad in
area (1) and (2).
Apply a thin coating of brake pad paste to T-head of outer brake pad in
area (1) and (2).

(model ranges: 5-Series, 6-Series, 7-Series, 8-Series, X1, X3, X5, Z4,
Rolls-Royce)



area (1 and 2).
area (1 and 2).

(model ranges: 5-Series, 6-Series, 7-Series, 8-Series, X5, Rolls-Royce)

Clean contact surface (1) and brake caliper with brake cleaner and apply

area (1 and 2).
area (1 and 2).
Collette brake (made by TRW), 1-piston brake caliper (model ranges:

MINI, 1-Series, 5-Series, 6-Series, Z4)

clean the guide surface (1) for the brake pads on the brake caliper
Apply a thin coating of brake pad paste to both sides of T-head of brake
pad in area (1).

ranges: MINI, 1-Series, 3-Series, 4-Series, 5-Series, 6-Series, 7-Series,
8-Series, X5, Rolls-Royce)
brake pad paste.
pad paste.
brake pad paste.

ranges: 1 Series, 2 Series, 3 Series; does not apply to M2 F87)
brake pad paste.
pad paste.
brake pad paste.

MINI F5x sport brake)

Clean brake caliper compartments (2) and apply a thin coating of brake
pad paste.
brake pad paste.
Do not grease the brake lining backplate and thoroughly clean it with
brake cleaner!
Only use new claw plates!
Slightly raise the protective film (1) at a place.
Insert the claw plates (1) into the brake pistons.
Pull off the protective film (1) with long-nose pliers (2).Attention!
The bonding surface of the claw plates must not be touched!
Install the brake caliper (1) in direction of arrow.

Parts: Replace screws (2).
Insert screws (2) and tighten.
Install the brake pad (1).Attention!
The brake pads must not touch the bonding surface of the claw
plates when inserting!
Apply the brake pads to the brake disc and insert.
In order to ensure a complete bonding of the claw plates with the

brake pads, the following instruction must be strictly adhered to:
Strongly press the brake pedal and hold it for at least 1 min!
Brake (made by Continental), 4-piston fixed caliper brake (model

ranges: 7-Series (G11, G12)
cleaner.
Always renew retaining plates 1!

Mount retaining plate 1.
It is paramount that the slide panels are correctly positioned in the
guides!
clean the guide surfaces for the brake pads on the brake caliper
mounting bracket.
Apply a thin layer of brake pad paste to the surfaces of the sliding plates
(1).

7-Series (G11, G12)
cleaner.
Adhesive residues must be completely removed.
To prevent damage to the surface coating, do not clean the guide

surfaces (1) for the brake pads on the brake calliper mechanically, if
possible.
Clean guide surfaces (1) with brake cleaner and apply a thin coating of
brake pad paste.
Remove the protective film of the adhesive layer (1) from the brake
pads.
Do not touch the adhesive layer!
Insert brake pads in the brake caliper, making sure the adhesive layer
does not touch the brake pistons.
Fit retaining clip (1).
Drive in the locking pins (2) in the direction of the arrow.
Attention!
After the brake pads have been installed they must immediately be
bonded to the brake pistons:
Step on the brake pedal to the floor and hold the pressure for
one minute. This causes the brake pads to adhere to the
brake pistons.
34 21 ... Layout of floating caliper (rear)
1 Brake-caliper housing 7 Guide bolt

2 Brake console 8 Protecting plug
3 Spring retainer 9 Brake-pad-wear sensor
4 Bolt 10 Seal set for brake caliper
5 Bleeder valve 11 Guide-sleeve repair kit
6 Dust cap 12 Brake linings repair set
34 21 812 Overhauling left or right rear brake caliper (brake caliper removed)
Note:
Use repair kit,
Take off plastic caps (1).

Installation:
Only clean guide screws; do not grease. Check guide bolts, replace
if necessary.
Dismantle brake caliper and remove brake linings.Installation:

Press brake lining fully outwards and insert spring (4).
Warning!
In the following work step, large forces occur at the brake caliper
piston (up to more than 2800 N!).
Danger of injury!
Press out piston with compressed air applied through connection bore.
To protect piston, place a protective plate (e.g. hard wood or hard felt) in
caliper recess.
Remove sealing ring carefully with a plastic needle.

Installation:
Apply a light coat of Ate brake cylinder paste to cylinder bore, piston
and sealing sleeve,
Install sealing cover in rear annular groove of cylinder bore.
Insert dust sleeve in front annular groove and press into annular groove
over entire diameter.Installation:
Area between dust sleeve and brake caliper housing must be kept
dry. It must not come into contact with Ate brake cylinder paste or
brake fluid so as to ensure that the dust sleeve is perfectly seated.
Support brake piston with commercially available extension and socket
and press gently onto dust sleeve.
Blow on sleeve with compressed air (max. 3 bar). Sleeve jumps over
brake piston.
Installation:
Coat dust sleeve and brake piston with brake fluid to facilitate
installation of dust sleeve.
34 21 171 Removing and installing/replacing a brake carrier/brake guard at
rear
Note:
When work is complete, adjust handbrake,
refer to 34 10 014.
Remove expander for handbrake shoe,
refer to 34 41 250.
Remove wheel hub (1),

refer to 33 41 151.
Release screws (2...3) and remove brake plate (4).
34 21 320 Removing and installing/replacing both brake discs

34 1 280

Remove wheels
If necessary, remove and clean brake pads.
Installation:
Adjusting parking brake

and measure.
Compare measurement result and lowest value with setpoint value.
Always replace brake discs in pairs.
If the brake discs are replaced, you must also fit new brake pads.
Important!
Note:
Release screws (1). Remove and suspend brake calliper from

vehicle.Note:
Brake hose remains connected.
Installation:
Unscrew bolts and take off brake disc.Installation:
Replace brake disc retaining screw.
34 21 200 Removing and installing/replacing both rear brake pads of disc
brake

34 1 050
34 1 280
Note:
When the repair work is finished, press the brake pedal a few times
so that the brake pads fit closely against the brake discs.
When installing new brake pads on the front axle with simultaneous
renewal of brake pads on the rear axle, check the brake fluid level, if
required top up to the "MAX" mark.
Remove wheels,
Important!
Brake pad wear sensor: after removal it must be replaced
(brake pad wear sensor loses its retention capability in the
break pad).
Retaining pins and expanding spring: for vehicles older
than 48 months it is recommended to replace the retaining
spring!
brake caliper mounting bracket. Instead, clean with brake cleaner
BMW part no. 83 19 2 154 780 and apply a thin coating of brake
pad paste BMW part no. 83 19 2 158 851 (3 g) or 83 19 2 158 852
(100 g).
Observe guideline for applying brake pad paste on brake pads
and brake anchor plate!
Remove plastic plugs (1).

Right:
Disconnect plug connection for brake pad wear sensor.
If necessary, replace brake pad wear sensor.
Installation note:
Only clean guide screws; do not grease.
Check threads.
Replace all guide screws which are not in perfect condition.
Lift out retaining spring (3).

Withdraw brake calliper backwards.
Turn piston back fully with special tool 34 1 050 .Important!

When turning back the piston, watch the brake-fluid level in the
expansion tank, as overflowing brake fluid will destroy the paintwork.
Remove outer brake pad.

Inner brake pad is located with its spring in the piston.
Important!
Mark any worn brake pads.
In the event of one-sided brake pad wear, do not change brake pads
round.
Observe minimum thickness of brake pads.
Clean brake pads.
Do not apply grease to brake lining backplate.
and measure.
Compare measuring result and lowest value with setpoint value.
Important!
Note:
Check dust boot for damage and renew if necessary.

Important!
Dust boot must not come into contact with anti‐squeak compound
as this may cause the dust boot to swell.
Clean contact surfaces (1) of T-heads/brake caliper housing with brake



clean the guide surfaces (1 and 2) for the brake pads on the brake caliper
area (1 and 2).
area (1 and 2).
34 21 745 Removing and installing/replacing left or right rear brake caliper
Remove rear wheel.
Caution!
fluid from emerging from the expansion tank and air from entering the
brake system when the brake lines are opened.
Release screws (1).

Installation:
Disconnect brake hose (2).

Unfasten brake hose on connection point to brake line.
Right:
Disconnect plug connection for brake lining sensor.
Pull off fist caliper towards rear of vehicle.
Installation:
Install brake hose without torsional stress.
First tighten the brake hose on the brake cover, then tighten
connection on brake line.
Caution!
Check routing and securing of brake-pad-wear indicator cable.
Check for correct securing with tab of dust cap. It is absolutely
essential to prevent the cable on the rim from being scuffed.
34 31 505 Removing and installing / replacing master brake cylinder for DSC
Note:
Refer to 34 00 ...
After completing tasks, bleed brake system,
ABS/DSC, refer to 34 00 050
Remove expansion tank,
refer to 34 31 181
Remove pressure sensor ”F” for DSC,
refer to 34 52 560
Remove pressure sensor ”R” for DSC,
refer to 34 52 555
Important!
Before beginning work, fully press the brake pedal several times to
reduce the vacuum pressure in the brake servo.
Release brake line (1).

1) Pre-charge pump circuit
Installation note:
Observe tightening torque,
refer to 34 32 1AZ
Release hexagon nuts (1) and pull brake master cylinder (2) out of brake
servo (3).Installation note:
Observe tightening torque,
refer to 34 31 1AZ
Installation note:
Replace O-ring (1).
Installation note:
When inserting the brake master cylinder (2) into the brake servo
(1), make sure the push rods of the brake servo (1) and the brake
master cylinder (2) lie in one plane.
34 31 500 Removing and installing / replacing the master brake cylinder
Caution!
refer to 34 00 ...
After completing work, bleed brake system,
ABS/ASC+T, refer to 34 00 048.
ABS/DSC3, refer to 34 00 050.
Remove expansion tank,
refer to 34 31 181.
Unfasten brake lines (1/2).

1) Circuit, front axle ”V”
2) Circuit, rear axle ”H”
Release hexagon nuts (3) and remove master brake cylinder from brake
booster.
Installation:
Tightening Torque,
Installation:
Do not tension flexible lines (1/2) between master brake cylinder
and hydraulic unit as this causes noises.
Installation:
Replace O-ring (1).
Installation:
When inserting master brake cylinder into brake booster, make sure
pressure rod of brake booster and pressure rod of master brake
cylinder are in one plane.
34 31 505 Removing and installing/replacing brake master cylinder for DSC
(MK60)
DSC (Dynamic Stability Control)Note:

Bleed brake system.
Remove expansion tank.
Remove pressure sensor ”V” for DSC.
Remove pressure sensor ”H” for DSC.
Detach brake lines (1).Installation:

Unfasten hex nuts (2).
Withdraw brake master cylinder (3) from brake booster (4).
Installation:
Installation:
Replace sealing ring in O-shape (1).
Installation:
When inserting brake master cylinder (2) into brake booster (1),
make sure that pressure rod of brake booster (1) and pressure rod
of brake master cylinder (2) lie on a single plane.
34 31 181 Removing and installing/replacing expansion tank for hydraulic
brake actuation
Note:
Follow general instructions:
Remove equipment compartment partition wall.
Suck the brake fluid out of the expansion tank. Use a suction bottle used
exclusively for drawing off brake fluid.
Do not reuse drawn off brake fluid.

Pull off supply hose (2) of clutch hydraulic system if necessary.
Release retaining screw (3).
Installation:
Pull expansion tank (4) vertically out of brake master cylinder.
Vehicles with DSC (before 09/00)

Release hose clip (1) and detach supply hose (2) of precharging pump
from expansion tank.
The supply hose must be secured in the vertical position so that no fluid
can emerge.
Caution!
Check rubber plug in brake master cylinder for damage and replace
if necessary.
Push the expansion tank vertically onto the master brake cylinder.
34 32 861 Replacing all brake pipes
Note:
The brake lines are only supplied in the straight version and correct
length with connecting nipple.
Refer to 34 00 ...
After completing repair work, bleed brake system
refer to 34 00 048
The new brake lines are bent into shape with bending tool 34 5 100.
Removed brake lines can be used as templates for bending.
Important!
Protective coating of brake line must not be damaged during
bending.
Do not kink or bend back brake lines.
Watch distances to rigid and movable vehicle parts.
Minimum of 5 mm to vehicle components fixed rigidly to
body.
Minimum of 10 mm to moving vehicle components.
Minimum of 10 mm to vehicle components fixed rigidly to
body, if brake line is fastened to moving vehicle
components (e.g. axle support).
Brake lines may not make contact or rub.
Tighten down brake line couplings with torque wrench.
Tightening torque, refer to Technical Data
34 32 971 Replacing both rear brake hoses
Note:
Note "General înformation",
refer to 34 00 ...
refer to 34 00 048.
fluid from escaping from expansion tank after brake pipes have been
disconnected (which would enable air to enter the braking system).
Release union nut (1); to do so, grip brake hose at square

drive.Installation:
Check retaining spring (3), replace if necessary.
refer to 34 32 1AZ.
Remove spring clip (1).

Pull lug of brake hose (1) in direction (2) out of fixture and remove
sideways in direction (3) out of fixture.
Installation:
When installing, make sure lug (1) rests against fixture (2).
Slide spring clip (3) into annular groove (4) as far as it will go.
Detach brake hose (1) from brake caliper.Installation:

refer to 34 32 1AZ.
Installation:
Mount and tighten brake hose on brake caliper first, then on brake
line/brake hose point of connection.
Never twist brake hose when installing it.
34 32 881 Replacing front left or right brake hoses
Caution!
After assembly, bleed brake,
refer to 34 00 048.
fluid from escaping from the expansion tank when the brake lines are
opened.
Disconnect brake hose from pipe.

Caution!
Brace brake hose on square head to ensure that the adapter
cannot rotate in the retaining bracket.
Unfasten brake hose from brake caliper.
Installation:
First tighten brake hose on brake caliper.
Move wheels into straight-ahead position.

Insert brake hose in bracket and screw onto brake pipe.
Tightening Torque,
Caution!
Never twist brake hose when installing it and avoid all contact with
parts attached rigidly to the body.
34 33 505 Removing and installing/replacing brake booster

Remove brake master cylinder.
Remove ABS/ASC+T hydraulic unit.
Remove DSC3 precharging pump.
Remove brake pedal.
Note:
Release nuts (1).Installation:

Carefully remove brake unit (1) from bulkhead and tilt out in direction of
engine.Note:
Do not use any force when removing and installing the brake unit;
the brake unit can be damaged under certain circumstances.
Remove brake unit vertically upwards out of equipment compartment.

34 33 505 Removing and installing/replacing brake unit (MK60)
DSC (Dynamic Stability Control)

Note:
General Information.
Bleed brake system with DSC.
Remove brake master cylinder for DSC (MK60).

Remove DSC hydraulic unit (MK60).
Remove brake pedal.
Unscrew nuts (1).

Installation:
Note:
Do not use any force when removing and installing the brake unit;
the brake unit can be damaged under certain circumstances.
Carefully remove brake unit (1) from bulkhead and tilt out in direction of
engine.
Remove brake unit vertically upwards out of equipment compartment.

34 33 051 Removing and installing/replacing non-return valve for brake unit
M47
Note:
refer to 34 00 ...
Before beginning work, actuate brake pedal several times to reduce
vacuum in brake booster to make it easier to pull off vacuum hose.
Open hose clip (1), detach vacuum hose (2) from non-return valve (3).
Remove non-return valve (3) from brake booster.
Installation:
Check seal for non-return valve, replace if necessary.
Replace hose clip (1).
34 33 071 Replacing vacuum hose for brake unit M47
Note:
refer to 34 00 ...
Before beginning work, actuate brake pedal several times to reduce
vacuum in brake booster to make it easier to pull off vacuum hose.
Remove heater bulkhead (1),
refer to 51 71 080.
Open hose clips (2/4), detach vacuum hose (3/5).Installation:

Replace hose clips.
34 10 014 Adjusting handbrake
Perform inspection in the following manner:

When 1st tooth is engaged, no braking effect should be present.
The differential of the wheel circumferential forces (left/right wheel)
may deviate by max. 30 % from the higher value (measured on the
brake analyzer).
In event of larger deviations of wheel circumferential force: Carry out
readjustment.
Braking with locked wheels must be possible with the parking brake.
The parking brake must be reset if the actuation stroke is greater
than 10 teeth.
Note:
Accurate adjustment of the parking brake is only possible if the
parking brake Bowden cables and all moving parts on the parking
brake move easily and function correctly.
Basic setting of the parking brake is required whenever:
- When replacing parking brake shoes.
- When replacing brake discs.
- Resetting adjustment unit.
- In event of excessive actuation stroke (10 teeth).
- When replacing parking brake Bowden cables
1. Setting instruction for brake shoes (basic setting)

Lever out gaiter for parking brake lever.
Release self-locking nuts on Bowden cables until tension is completely
released.
Use a tubular hexagon box wrench or a long socket for this task.
Completely unscrew one wheel stud on each rear wheel.

Turn wheel until adjustment screw is visible in tapped hole.
Installation:
Install and tighten wheel bolt.
Turn adjusting screw with a screwdriver until the wheel is no longer able
to turn.
Then unfasten the adjusting screw 10 notches.
2. Setting instruction for parking brake Bowden cables

After basic setting has been completed, the adjustment nuts must be
uniformly hand-tightened before the Bowden cables are adjusted.
Then the parking brake lever must be applied 5 times to approx. 400 N
actuation force with the release button pressed.
2.1 By hand
Apply 2 teeth of parking brake lever and adjust adjusting nuts until
braking action begins.
Release parking brake. Wheels must be able to be freely turned.
Switch on ignition. Indicator lamp must be off with parking brake released.
1st No braking effect. Indicator lamp can be lit.
tooth:
2nd Braking effect must start. Indicator lamp must be lit. If the
tooth: indicator lamp is not lit, the switch contact on the parking brake
lever must be adjusted.
2.2 On brake analyzer

0th tooth
(parking brake Vehicles with manual transmission: Shift lever in
released): neutral position.
Vehicles with automatic transmission: Selector
lever position ”N”.
Wheel circumferential force at idle ≤ 150 N.
1st tooth: No brake force increase; indicator lamp can be lit.
2nd tooth: Indicator lamp must be lit.
3rd tooth: Increase in braking force.
4th tooth: Adjust parking brake Bowden cables until brake
force indicator shows that ≥ 550 N has been
reached.
3. Braking in the duo-servo parking brake
The following braking-in procedures are applicable in case of insufficient
braking effect or after replacing brake discs and/or brake shoes.
3.1 On brake analyzer

Actuate parking brake lever until the wheel circumferential force on both
wheels is at least 800 N.
Release parking brake lever after approx. 40 seconds.
3.2 When driving on road

(Where possible on factory premises or quiet road)
At approx. 40 km/h actuate parking brake lever until a braking effect can
be felt.
Pull parking brake lever to next notch and drive on for approx. 400 m.
A basic requirement is that parking brake is adjusted uniformly.
Note:
If necessary, repeat braking-in procedure. Allow brake to cool down
sufficiently.
34 00 ... General information on braking in new brake discs / brake pads
Important!
Carry out function check on brake test stand to ensure that
the brakes complies with legal requirements.
Carry out test braking while driving at low speed; the
effectiveness of the brakes may be reduced during the initial
braking operations.
Exaggerated drastic and continuous braking operations for
faster braking in are not permitted.
Advise the customer not to perform any wilful drastic braking in
the first 200Â km after brake replacement.
Attach mirror tag to interior rearview mirror.
34 41 220 Removing and installing/renewing all parking brake pads

Remove rear brake disc,
Adjust the parking brake after having finished repair work.Note:

During replacement of the hand brake coverings, the following
components must also be renewed:
Brake shoe expander
Adjusting screw
Spring set
Disconnect return spring (1) with brake spring pliers.Installation note:

Check return spring (1), replace if necessary.
The graphic shows right side, left side as a mirror image.
Pay attention to installation position of adjusting screw (2).
Apply a thin coat of grease to bush and screw threads,
see BMW Service Operating Fluids.
Disconnect return spring (1) with brake spring pliers.Installation note:

Check return spring (1), replace if necessary.
Detach roll pin (1) using special tool 34 4 000 and rotate by 90Â°.
Remove brake pads (2).
34 41 120 Removing and installing/replacing both handbrake bowden cables

Remove complete exhaust system
After completing tasks, adjust handbrake.
Release lock nuts with special tool 34 1 030. Twist lock nuts and
adjusting nuts off handbrake bowden cables. Installation:
Observe adjusting instructions and lock adjusting nuts with lock
nuts.
Remove heat protection shield (1) on tank.
Pull handbrake Bowden cable (1) out of brackets.Installation:

Ensure proper routing of handbrake Bowden cables.
Pull handbrake bowden cables out of guide tubes on body and out of
wheel carrier.
Release one wheel stud.

Bring wheel into position (tapped hole turned down approx. 20° from
horizontal).
F = direction of travel
Installation:
Reinstall wheel stud only after handbrake has been adjusted.
Nipple (1) and expander lock (2) are visible through tapped hole.
Push in core of handbrake cable in direction of expander lock as far as it
will go and grip firmly.
Press nipple (1) downwards through tapped hole with a screwdriver.
Pull out handbrake bowden cable.
Installation:
Insert handbrake bowden cable in brake carrier/brake guard plate.
Sleeve must be inserted up to stop.
Grip sleeve of handbrake bowden cable.
Push in core until it snaps into place.
34 41 250 Removing and installing/replacing brake shoe expander for
handbrake shoes
Note:
Remove rear wheel,
refer to 36 10 300
Remove rear brake disc,
refer to 34 21 320
Remove handbrake pads,
refer to 34 41 220
Installation:
After completion of work, adjust parking brake,
refer to 34 10 014
Pull brake shoe expander (1) forwards, disconnect handbrake cable (2)
and remove brake shoe expander.
34 41 000 Removing and installing/replacing handbrake lever

00 2 222
Remove storage tray.

If necessary, remove center armrest.
Installation:
Adjust handbrake after completing work.
Follow adjustment instructions.
Disconnect lines to handbrake indicator switch.

Release adjustment nuts with special tool 00 2 222 and screw down fully
from Bowden cables.
Installation:
Use new screws.
Release screws (1 and 2).

Remove handbrake lever.
34 51 525 Removing and installing / replacing hydraulic unit ABS/ASC+T
Note:
Follow general instructions,
refer to 34 00 ...
Before starting work, read out fault memory of ABS/ASC+T control
module and print out diagnostic record.
After completing work, carry out function test on ABS/ASC+T unit, refer to
BMW Diagnosis Information System (DIS).
refer to 34 00 048.
Removing end firewall,

refer to 51 71 080.
Remove seal (1) towards top.
Remove vacuum line and B+line from assembly compartment partition

wall.
Turn seals (1) through 90° and thus unlock. Remove assembly
compartment partition wall (2) towards top.
Installation:
When installing the vacuum line and B+line, ensure rubber
grommets are correctly seated.
Remove master brake cylinder,
refer to 34 31 500
Detach lines (1...6), seal connection bore with plugs.

V) From THZ circuit V to ABS/ASC+T unit circuit V (front axle circuit)
H) From THZ circuit H to ABS/ASC+T unit circuit H (rear axle circuit)
FR) From ABS/ASC+T unit VR to wheel brake front right
FL) From ABS/ASC+T unit VL to wheel brake front left
HR) From ABS/ASC+T unit HR to wheel brake rear right
HL) From ABS/ASC+T unit HL to wheel brake rear left
Installation:
refer to 34 32 1AZ

Remove brake lines with rubber grommet from metal body and press in
direction of engine. Do not under any circumstances bend brake lines.
Release hexagon screw (2) and remove ABS/ASC+T unit towards top.
Installation:
Ensure that rubber grommet is correctly seated when installing
brake lines.
Installation:
Check rubber mount (1) for correct seating. Replace damaged
rubber mount.
Replacing hydraulic unit
Release screws (1) and carefully detach control module (2) from
hydraulic unit (3).
Installation:
Replace micro-encapsulated screws.
refer to 34 51 1AZ.
Release screws (1).
Release screw (1) and remove bracket (2) from hydraulic unit (3).
34 51 550 Removing and installing pre-boost pump DSC3
Note:
Bleed the brake system after completing the work,
refer to 34 00 050
Draw brake fluid out of expansion tank.
Remove end fire wall,
refer to 51 71 080.

wall.
Installation:
Release union nuts (1 and 2), unlock and disconnect plug connection
(3).Installation:
Pipe, (1) refer to 34 32 1AZ.
Intake pipe (2), refer to 34 51 5AZ.
Unlock plug (1) and remove from retainer.
Remove pre-boost pump (4) in direction 2 from rubber mount.
Remove pre-boost pump (4) in direction 3 from bracket (5).
Installation:
34 51 527 Removing and installing/replacing DSC hydraulic unit
Note:
refer to 34 00 ...
After completing work, carry out function check on DSC unit, refer to
BMW Diagnosis Information System (DIS).
refer to 34 00 050.
Detach lines, seal connection bores with plugs.
V) from THZ circuit V to DSC unit circuit V (front axle circuit)

H) from THZ circuit H to DSC unit circuit H (rear axle circuit)
FR) from DSC unit VR to wheel brake front right
FL) from DSC unit VL to wheel brake front left
HR) from DSC unit HR to wheel brake rear right
HL) from DSC unit HL to wheel brake rear left
Installation:
refer to 34 32 1AZ.

Release screw and feed out DSC unit towards top.
Replacing hydraulic unit

Release screws (1) and remove bracket (2) from hydraulic unit (3).
Release screws (1) and detach control module from hydraulic
unit.Installation:
refer to 34 51 1AZ.
34 51 527 Removing and installing/replacing DSC hydraulic unit (MK60)

Note:
First read out fault memory of control unit and if necessary print
diagnostic record.
Installation:
On completion, carry out following tasks with the DIS (Diagnosis and
Information System):
If control unit is new: Coding
If control unit is new: Adjustment of steering angle sensor, pressure
sensors and transversal acceleration sensor
Function check, hydraulic unit
Bleed brake system.
Caution!
Do not mix up brake lines, mark prior to removal if necessary.
Seal off connection bores with plugs.
Remove brake master cylinder for DSC (MK60).

Disconnect plug connection (1) to control unit.
Release brake lines (F and R).
(F) from THZ circuit F to hydraulic control unit circuit F (front-axle circuit)
(R) from THZ circuit R to hydraulic control unit circuit R (rear-axle circuit)
Installation:
Unfasten brake pipes.

(FR) from hydraulic control unit FR to front right wheel brake
(FL) from hydraulic control unit FL to front left wheel brake
(RR) from hydraulic control unit RR to rear right wheel brake
(RL) from hydraulic control unit RL to rear left wheel brake
Installation:
Release screw (1) and feed out DSC unit with retaining fixture towards
top.
34 52 525 Removing and installing/replacing ABS front pulse generator
(MK60)
Open plug housing (1), pull plug connection (2) out of fixture and
disconnect.
Pull cable with rubber grommet out of fixture on spring strut and on body.
Installation:
Make sure plug connection is properly engaged and rubber
grommet is correctly seated.
Release hexagon socket screw (1).

Withdraw ABS pulse generator (2) from bore hole.
Installation:
Installation:
There are different pulse generators for the MK60.
Pulse generators are marked ”R” (right) and ”L” (left).
Right pulse generator has two green markings between sensor and
grommet.
Installation:
Clean hole for pulse generator and grease with lubricating grease
Staburags NBU 12/K (refer to BMW Service Operating Fluids).
34 52 515 Removing and installing/replacing control unit for ABS/ASC+T
Important!
Read and comply with notes on protection against electrostatic
damage (ESD protection).
Before starting work, read out fault memory of ABS/ASC+T control unit
and print out diagnostic record.
Remove and install ABS/ASC+T unit,
Refer to 34 51 525
To remove the ABS/ASC+T unit, seal the line connections with the plugs
provided in the repair kit. This prevents brake fluid from being discharged
from the hydraulic unit, which in turn makes it easier to bleed the brake
system later.
Release screws (1) and carefully detach control unit (2) from hydraulic
unit (3).Installation:
Note tightening torque,
Refer to 34 51 1AZ.
34 52 516 Removing and installing/replacing control unit for DSC
Important!
Before starting work, rear out fault memory of ABS/DSC control unit and
print out diagnostic record.
Remove diagnosis socket from fixture and place to one side.

Release screws (1) and carefully remove control unit (3).
Installation:
Note tightening torque,
Refer to 34 51 1AZ.
34 52 516 Removing and installing/replacing control unit for DSC (MK60)
Important!

First read out fault memory of control unit and if necessary print
diagnostic record.
Remove DSC hydraulic unit.
Important!
Removing pump motor from valve block is not permitted!
To remove the DSC unit, seal off the line connections with the plugs (1)
provided in the repair kit. This prevents brake fluid from being discharged
from the hydraulic unit, which in turn makes it easier to bleed the brake
system later.
Secure provided retaining lug (2) from repair kit for pump motor with aid of
plugs (3).
Loosen screws (1).

Carefully detach control unit (2).
Installation:
34 52 550 Removing and installing/replacing DSC angular rate sensor
Important!
discharge (ESD protection).

Remove front left seat.
Remove footwell trim panel from A-pillar, left.
Raise carpet (1).

Move insulating material (2) forward until angular rate sensor (3) is
accessible.
Release screws (1).

Loosen screws (2) of holder (3).
Important!
Vibration-sensitive component.
Implement screw connection correctly, otherwise there may be
malfunctions in the DSC.
Installation note:
Swing angular rate sensor (1) in direction (2) upward and remove in
direction (3).
Release screws (2) and remove angular rate sensor from bracket.
Important!
Vibration-sensitive component.
Implement screw connection correctly, otherwise there may be
malfunctions in the DSC.
Installation note:
34 52 525 Removing and installing/replacing front pulse generator
Important!
Open plug housing (1), pull plug connection (2) out of fixture and
disconnect.
Pull cable with rubber grommet out of fixture on spring strut and on body.
Installation:
Ensure proper locking of plug connector and proper seating of
rubber grommets.
Release hexagon socket screw (1).

Withdraw wheel speed sensor (2) from bore hole.
Installation:
Installation:
Clean bore hole for pulse generator and grease with Staburags
NBU 12/K lubricating grease (refer to BMW Service Operating
Fluids).
34 52 555 Removing and installing/replacing pressure sensor "H" for DSC
Note:
Note "General Information",
refer to 34 00 ...
Caution!
After replacing the pressure sensor, carry out a calibration with DIS
(Diagnosis and Information System) under menu item ”Service
functions”.

refer to 34 00 050.
Remove heater bulkhead,
refer to 51 71 080.
Remove expansion tank for brake fluid,
refer to 34 31 181.

wall.
Installation:
Detach pipe (1) from intermediate piece (2) and from master brake
cylinder (3). Remove pipe with rubber grommet.Installation:
refer to 34 32 1AZ
Ensure that rubber grommet is correctly seated.
Detach pressure sensor (2) from master brake cylinder (3).
Installation:
refer to 34 51 2AZ.
34 52 560 Removing and installing/replacing pressure sensor "V" for DSC
Note:
Note "General Information",
refer to 34 00 ...
Caution!
After replacing the pressure sensor, carry out a calibration with DIS
(Diagnosis and Information System) under menu item ”Service
functions”.

refer to 34 00 050.
refer to 51 71 080.
Remove expansion tank for brake fluid,
refer to 34 31 181.

wall.
Installation:
Detach pipe (1) from intermediate piece (2) and from master brake
cylinder (3). Remove pipe with rubber grommet.Installation:
refer to 34 32 1AZ
Ensure that rubber grommet is correctly seated.
Detach pressure sensor (2) from master brake cylinder (3).
Installation:
refer to 34 51 2AZ.
34 52 535 Replacing a rear pulse generator
Important!

Remove wheel
Remove lip (2).Installation:

Pay attention to guide (1).
Open plug housing (1).

Pull plug connection for wheel speed sensor out of fixture and
disconnect.
Open cable holder (1).

Pull cable out of fixtures on trailing arm.
Cable routing up to 03/02:
Open cable holders (1). Pull cable (2) out of fasteners on rear swinging
fork.
Important!
If a trailing arm is replaced and there is no bore hole for the holders,
it is necessary to lay the cable as in vehicles from 03/02 through the
trailing arm.
Cable routing from 03/02:

Open cable holder (1).
Feed cable out of fixtures and through trailing arm (2).
Release hexagon socket screw (1). Withdraw wheel speed sensor (2)
from bore hole.Installation:
Clean bore hole for pulse generator and grease with Staburags
NBU 12/K lubricating grease (refer to BMW Service Operating
Fluids).
equipment)
Warning!
Important!
direct sunlight.
Important!
Important!
fumes directly.
agent/paint.
cream.
Important!
First Aid:
Recycling:

temperature.
Installation note:
curing)
35 11 000 Removing and installing mounting block for pedals
Caution!
If a brake pedal without a retaining bracket (which encloses the
piston rod) is fitted, if must be replaced by a brake pedal with a
retaining bracket.
Remove panel for pedal assembly.

Remove brake pedal.
If necessary, remove clutch switch.
Installation:
Make sure plug connections engage correctly.
Unhook return spring from clutch pedal.

Press pin ends together and withdraw pin (2).
Release screws (1) on clutch master cylinder.
Remove retaining plate for brake light and clutch switches.
Release nuts (1) and remove bearing block (2).
Installation:
Tighten nuts (1) in front of nut (2).
Tightening torque, 35 11 1AZD.
35 31 000 Removing and installing or replacing clutch pedal

Refer to MG 51.
If applicable, remove clutch switch.
Disconnect return spring.

Press bolt ends (1) together and remove bolt.
Remove retainer (2) and detach clutch pedal from bearing pedestal.
Installation:
Check bearing bushes (1) and replace if necessary.
Lightly grease bearing bushes (1),

Replace rubber grommet (2) if necessary.
35 21 000 Removing and installing/replacing brake pedal
Important!
If a brake pedal without a retaining bracket (which encloses the
piston rod) is fitted, if must be replaced by a brake pedal with a
retaining bracket.
Remove panel for pedal assembly.

Remove brake light switch.
Brake pedal without retaining bracket
Detach retainer and disconnect piston rod.Installation:

Use new retainer.
The retainer must be seated with both legs in the pin groove.
The workshop supervisor must mark the retainer with a dot of red
paint (1) thereby acknowledging correct installation.
Detach retainer (1) and pull brake pedal off bearing block. If necessary, tilt
panel (2) upwards.
Installation:
Attach new retainer (1).
Installation:
Brake pedal with retaining bracket

Detach retainersÂ (1).
Installation:
Use new retainers (1).

Pull bearing bushing (1) out of brake pedal and press to left.
Twist brake pedal (2) downwards out of mounting in direction of arrow.
Installation:

35 31 000 Removing and installing or replacing clutch pedal

Refer to MG 51.
If applicable, remove clutch switch.

Press bolt ends (1) together and remove bolt.
Remove retainer (2) and detach clutch pedal from bearing pedestal.
Installation:

Replace rubber grommet (2) if necessary.
35 40 001 Removing and installing/replacing accelerator pedal module
Installation:
Accelerator pedal modules for vehicles with manual and automatic
transmissions are different. Accelerator pedal module for automatic
vehicles can be identified by its increased pressure point in full-load
position.
Lever lock downwards with a screwdriver and detach accelerator pedal

module to one side.
Press together lock and detach plug.
Installation:
Slide accelerator pedal module first at bottom (1) and then at top (2) into
guide rails. Mandrel of adapter plate (3) must penetrate into
corresponding opening in accelerator pedal module.
In the end position, the right outer surfaces of the adapter plate and the
accelerator pedal module are flush and the lock of the adapter plate is
snapped into place twice.
35 40 503 Replacing adapter plate
Warning!
Always replace disassembled adapter plate with a new part.
Retaining clips of old part can be damaged and adapter plate can
slide out of steel plate.
This means there is a risk of accident!
Remove accelerator pedal module.

Release screw (1).
Installation:
Bend retaining clips (2 and 3) to one side and pull out adapter plate
towards top.
35 41 000 Removing and installing/replacing accelerator pedal
Warning!
Once an accelerator pedal has been removed, always replace it
with a new pedal!
Retaining clips on old part may be damaged. Foot pedal can then
Press down carpet.

Press locking tab (1) forwards.
Installation:
Fold locking tab (1) upwards until it engages.
Bend retaining clips forwards and lever out foot pedal upwards.
Installation:
Insert foot pedal in floor with pocket on steel plate.
Retaining clips must snap into place.

Check without fail that retaining clips have snapped into place!
Turn accelerator pedal until linkage lug of pedal engages in opening and
remove pedal.Installation:
Lightly grease sliding surface of accelerator pedal.
35 41 010 Removing and installing/replacing accelerator pedal

Refer to MG 51.

Release nuts and pull holder towards interior.
Installation:
Press down locking hook and pull accelerator pedal off holder.
Installation:
Check bearing bushings (1), replace if necessary and lightly grease.
Unhook throttle cable from accelerator pedal.

Tilt accelerator pedal down and remove from pedal.
35 40 001 Removing and installing/replacing accelerator pedal module
Installation:
Accelerator pedal modules for vehicles with manual and automatic
transmissions are different. Accelerator pedal module for automatic
vehicles can be identified by its increased pressure point in full-load
position.
Lever lock downwards with a screwdriver and detach accelerator pedal

module to one side.
Press together lock and detach plug.
Installation:
Slide accelerator pedal module first at bottom (1) and then at top (2) into
guide rails. Mandrel of adapter plate (3) must penetrate into
corresponding opening in accelerator pedal module.
In the end position, the right outer surfaces of the adapter plate and the
accelerator pedal module are flush and the lock of the adapter plate is
snapped into place twice.
35 41 020 Removing and installing/replacing bracket for accelerator pedal
Remove lower section of steering spindle,

refer to 32 31 070.
Refer to MG 51.
If necessary, remove pedal travel sensor,
refer to MG 13.

Release nuts and pull holder towards interior.
Installation:
Press down locking hook and pull accelerator pedal off holder.
Installation:
Check bearing bushings (1), replace if necessary and lightly grease.
Lift crash sleeve (2) out of groove of steering spindle.
Push steering spindle up until bracket can be removed.
35 40 503 Replacing adapter plate
Warning!
Always replace disassembled adapter plate with a new part.
Retaining clips of old part can be damaged and adapter plate can
Remove accelerator pedal module.

Release screw (1).
Installation:
Bend retaining clips (2 and 3) to one side and pull out adapter plate
towards top.
36 10 209 Checking front and rear wheel for face and radial runout

36 1 030
Important!
Wheel bearing must be OK!
Lift vehicle.
Check wheel with special tool 36 1 030 (measuring fixture) for lateral
runout.
Check wheel with special tool 36 1 030 (measuring fixture) for radial
runout.
If applicable, remove balance weights.

Check lateral runout of rim with special tool 36 1 030 (measuring fixture).
Check radial runout of rim with special tool 36 1 030 (measuring fixture).
36 10 713 Checking one road wheel on balancing machine for face and
radial runout (wheel removed)

36 1 030
36 1 031
36 1 032
36 1 033
36 1 034
36 1 035
36 1 036
Remove wheel.
Mount wheel in balancing machine.
In order to avoid transformation errors, the wheel must be mounted on
the balancing machine in the same manner as subsequently mounted on
the car (e.g. valve facing down).
Use suitable wheel centre supplied with corresponding balancing

machine.
1. Basic flange
2. Centre
3. Type flange
4. Clamping nut
Also refer to Workshop Equipment and Planning documentation.
Use special tool 36 1 030 for testing.

Special tool 36 1 030 consists of:
(1) Stand 36 1 031
(2) Post with clamp 36 1 032
(3) Holder with clamp 36 1 033
(4) Clamp 36 1 034
(5) Measuring roller 36 1 035
(6) Dial gauge 36 1 036
Position special tool 36 1 030 on tire tread.
Turn wheel by hand and measure max. tire radial runout,
refer to Technical Data
Note:
Measuring device must be vertical to tire tread.
Position special tool 36 1 030 on tire sidewall.

Turn wheel by hand and measure max. tire face runout,
Note:
Measuring device must be vertical to tire sidewall.
Never measure on printed text on tire!
If necessary, check disk wheel (rim) for radial and face runout.
36 10 715 Checking rim for face and radial runout
Remove wheel.
Check front or back wheel for face and radial runout.
Pull tire off rim.
Remove fitted balancing weights.
Remove dirt from rim well and rim flange.
Mount disk wheel in balancing machine.

machine.
1. Basic flange
2. Centre
3. Type flange
4. Clamping nut
Place dial gauge sensor on rim shoulder.

Turn wheel by hand and measure maximum radial runout,
Carry out measurement on both rim shoulder sides.
Note:
Dial gauge must be vertical to rim shoulder.
Position sensor on rim flange.
Turn wheel by hand and measure maximum lateral runout,
Carry out measurement on both rim flanges.
Note:
Dial gauge must be vertical to rim flange.
Important!
Avoid transformation errors during subsequent installation tasks.
36 12 ... Notes and specifications for tyre / wheel exchange
General:
The tyre size, manufacturer and tyre tread must be the same on one axle
To meet the BMW standards, the vehicle should be equipped with tyres from the same manufacturer and
with the same tyre tread (tyres approved by BMW) on all 4 wheels
The difference in tyre tread depth on one axle must not exceed 2 mm (control quality of suspension
control systems and wheel alignment requirement)
The tyres with the higher tread depths must be mounted on the rear axle
The DOT age difference must not exceed 4 years
The tyre pressure must be adjusted when the tyres are exchanged
Wheel exchange between the axles
The wheels may be exchanged between axles to achieve even abrasion. However, BMW does not
recommend switching the front wheels to the rear or vice-versa.
The wheel exchange may lead to the following customer complaints:
complaints regarding acoustics
Risk of increased lane groove sensitivity
Compliance with the following requirements is required when exchanging wheels between the axles:
Assess the wear pattern
The tread difference between the front and rear wheels must not exceed a maximum of 2-3 mm
Exchange the wheels between the axles every 5000 Km
Additionally for all-wheel drive vehicles:

The tyre size, manufacturer and tyre tread must be identical on all wheels; different tyre sizes between
front and rear axles are only permissible if mixed tyres are fitted.
The tyre tread difference between tyres in all wheel positions must not exceed 2 mm (normal quality of
the wheel control systems and wheel alignment requirement)
36 10 300 Remove or install front or rear wheel

81 25 2 344 011
36 1 300
36 1 335
36 2 010
Attention!
The wheel is balanced electronically.
contact surfaces between brake disc and disc wheel and between
brake disc and wheel hub must be free of grease.
When fitting all four wheels (e.g. when changing from summer to
winter wheels), check the tyre inflation pressure.
To avoid tyre damage, advise the customer to check the tyre
pressures on a regular basis (see operating instructions).
Observe the following in order to avoid clamping errors and imbalance:

Loosen the wheel studs.
Wheel positioned with valve facing down.
If several wheels are simultaneously removed, mark installation
position of wheels on tyres (e.g. with a piece of chalk).
Mark out wheel to wheel hub.
Mark out lockable wheel stud in relation to wheel.
Release wheel studs and remove wheel.
Remove dirt, grease residues and corrosion from contact surface with a
drill and special tool81 25 2 344 011 .Attention!
Do not operate special tool 81 25 2 344 011 with an impact
screwdriver!
Note:
Degrease contact surface with universal cleaner, refer to BMW
Parts Department.
Note:
If there are grease residues in the area of the wheel stud hole, the
brake disc must be removed and cleaned.
Remove dirt, grease residues and corrosion from contact surface with a
drill and special tool 81 25 2 344 011 .Attention!
Do not operate special tool 81 25 2 344 011 with an impact
screwdriver!
Note:
Degrease contact surface with universal cleaner, refer to BMW
Parts Department.
Check brake disc retaining bolt (1) for tight fit. Attention!
Brake disc retaining bolt must under no circumstances protrude
over contact surface (2) between brake disc and disc wheel.
Tightening torque, brake disc retaining screw,
Front axle, refer to 34 11 1AZ .
Rear axle, refer to 34 21 1AZ .
Apply a thin coat of grease to wheel centring (1) in disc wheel.Note:

Refer to BMW Service Operating Fluids, Main Group 36.
Note:
To release and tighten lockable wheel bolts, use a matching adapter
from special tool 36 1 300 , 36 1 335 or 36 2 010 .
Clean wheel bolts and check threads for damage, renew if necessary.
Renew corroded wheel bolts.
Attention!
Do not apply oil to wheel studs.
Attention!
Under no circumstances use pneumatic or electric screwdrivers to
screw in and tighten the wheel bolts.
Attention!
Disc wheel must rest uniformly against brake disc.
In the case of non-original BMW wheel studs/rims it may be
necessary to retighten the wheel studs on account of setting
properties (refer to manufacturer's documents).
Screw in wheel studs and, to centre disc wheel, tighten down by hand
diagonally and evenly.
Tighten wheel bolts to the prescribed tightening torque with a calibrated
torque wrench in a crosswise sequence.
Installation note:
Tightening torque, refer to 36 10 1AZ .
36 10 508 Stationary wheel balancing

36 1 010
36 1 020

Remove wheel
Important!
Use only BMW-approved balance weights.
Remove old balance weights, stones in treads and larger pieces of dirt.
Check tyre pressure, check tyre for condition, damage, flat spots (out-of-
round caused by e.g. stopping the car with hot tyres); if necessary, check
wheel and tyre for radial and lateral runout.
Use BMW-approved centering elements of relevant balancing machine

manufacturers.
1. Basic flange
2. Wheel centering element
3. Type flange
4. Clamping nut
Also refer to section on Workshop Equipment.
Important!
To avoid retooling errors, it will be necessary to fit the wheel on the
balancing machine in the same way (e.g. valve facing down) as it is
then fitted on the car.
Balance wheel in accordance with operating instructions of relevant

balancing machine.
On light-alloy rims with distinctive J-shape rim flange, proceed as follows:
1. Gently force off tyre sidewall with special tool 36 1 020 at
appropriate point from rim flange.
2. Install retaining clip (1).
3. Remove special tool 36 1 020 .
Raise retaining clip with special tool 36 1 010 . Slide balance weight
underneath and allow it to snap into place.
Arrangement of balance weights for light-alloy rims with distinctive J-

shape rim flanges.
1. Spring retainer
2. Balance weight
Adhesive weights must be used on all other light-alloy rims.
Max. out-of-balance per wheel
Note:
When using adhesive weights, proceed as follows:
1. Carefully remove old adhesive weights. Do not damage rim when

doing so.
2. Select suitable location for fitting.
3. Clean adhesive area thoroughly.
36 10 715 Checking rim for face and radial runout
Remove wheel.
Check front or back wheel for face and radial runout.
Pull tire off rim.
Remove fitted balancing weights.
Remove dirt from rim well and rim flange.
Mount disk wheel in balancing machine.

machine.
1. Basic flange
2. Centre
3. Type flange
4. Clamping nut
Place dial gauge sensor on rim shoulder.

Turn wheel by hand and measure maximum radial runout,
Carry out measurement on both rim shoulder sides.
Note:
Dial gauge must be vertical to rim shoulder.
Position sensor on rim flange.
Turn wheel by hand and measure maximum lateral runout,
Carry out measurement on both rim flanges.
Note:
Dial gauge must be vertical to rim flange.
Important!
Avoid transformation errors during subsequent installation tasks.
36 00 ... General Information, Series light alloy disk wheel E 46
Note: All E 46 vehicles are fitted as standard with light alloy disk
wheels which it is difficult to distinguish visually from steel disk
wheels.
Sticker on light alloy disk wheel. (1) = Indication ”Aluminium”
Wall thickness of rim dish: approx. 8 mm.
Light alloy disk wheels are not magnetic.
Light alloy disk wheels can be identified from their BMW parts
numbers, refer to BMW Parts Service.
Caution!
Use only special hub caps for E46. When using different hub
caps, these can be damaged by the smaller diameter of the
clamping surface, resulting in loss.
Use only BMW-approved two-part balancing weights.
When fitting two-part balancing weights, always use specified
tools.
Do not straighten light alloy disk wheels: always replace
damaged light alloy disk wheels.
Notches in light alloy disk wheels can lead to cracking.
Do not lubricate wheel nuts.
When fitting tires, avoid damaging light alloy disk wheels, e.g.
on sharp-edged retaining claws on fitting machine.
36 11 533 Removing and installing / replacing RDC wheel electronics
Note:
If a tyre sealant has been used, replace the wheel electronics.
When a tyre has been removed, do not clean the rim with installed wheel
electronics with high-pressure cleaning equipment.
Do not treat wheel electronics with solvents, cleaning agents etc. If dirty,
wipe with a clean cloth only.
Do not clean wheel electronics with compressed air.
Important!
If the wheel electronics have been removed, the complete valve
must be replaced.

Remove tyre
Follow instructions on initializing Run Flat Indicator.
Labelling of wheel electronics

1 Transmitting frequency of wheel electronics
2 Large Torx socket
3 BMW part number
4 Tightening torque of Torx screw and union nut
5 Width across flats of union nut
6 Identification code of wheel electronics
7 Date of manufacture of wheel electronics
Removing wheel electronics

Release Torx socket screw (1).
Remove wheel electronics (2).
Check filter surface (1) for pressure measurement for
contamination.Note:
Wipe filter surface with a clean cloth only.
The wheel electronics must be replaced if the filter surface is
contaminated.
Release union nut with special tool 00 2 190; if necessary, grip valve
insert (1) at cylindrical section of ball head.
Remove valve insert from rim.
Remove washer (1).
Installing wheel electronics

Insert new Torx socket screw (1) in wheel electronics (2) and secure
firmly.
Twist new valve insert (3) by hand approx. 3 turns onto screw.
Note:
Do not tighten screw; wheel electronics and valve insert must be loosely
joined together.
Insert valve insert with wheel electronics into cleaned valve bore.
Here the radial bore for gripping on the circumference of the valve insert
ball head must point outwards.
Insert the brace supplied with the valve into the valve insert bore.
Fit new washer and screw on new union nut by hand as far as it will go.
Tighten down union nut, using brace to prevent valve insert from twisting.
Important!
The screw connection must be tightened to the specified torque in
one go!
Do not under any circumstances retighten the screw connection!
Remove brace, otherwise it may damage the tyre.
Press wheel electronics gently into well base and tighten Torx socket
screw (1).
Important!
The screw connection must be tightened to the specified torque in
one go!
Do not under any circumstances retighten the screw connection!
36 11 522 Removing and installing/replacing front receiving antenna for
RDC
Front left
Remove panel (1).

Release screws (2) and remove receiving antenna (3).
Front right
Release panel (1) and carefully pull towards rear.
If necessary, disconnect plug connection on outside temperature
sensor.
Release screws (1) and remove receiving antenna (2) from panel (3).
36 11 520 Removing and installing/replacing RDC control unit
Important!

Remove glovebox
Remove panel (1).

Press retaining hook (2) downwards and remove control unit (3) towards
rear from control unit carrier.
36 11 527 Removing and installing/replacing rear receiving antenna for RDC
Release panel (1) and carefully pull towards front.

Remove screws (1) and receiving antenna (2) from panel (3).
36 12 001 Changing a tyre (on front, rear or spare wheel)
Important!
Vehicles with navigation system 1 (up to 9/97):
When exchanging/replacing tyres, or when changing to other tyre
sizes, a wheel calibration must be carried out in the navigation
system.
Follow instructions on initializing Run Flat Indicator.
Refer to the operating manual of the relevant fitting equipment

manufacturer for details on how to fit the tyre correctly. The equipment
must be in perfect condition to exclude the risk of damaging the disk
wheel and the tyre.Note:
Comply with approved tyres, tyre sizes and optional extra.
Note:
Pay attention to different tyre markings:
Item (1) Marking denoting BMW-approved tyres. Ensure that only
BMW-approved tyres are fitted.
Item (2) RSC is the abbreviation for Runflat System Component
(runflat tyres).
Item (3) Outside. The tyre must be fitted so that the wording
Outside is always situated on the outside of the rim.
Important!
Many tyres are directional!
The arrow on the tyre must point in the direction of travel for each
wheel!
Models with M Mobility system
If the tyre was filled with the M-Mobility system after a puncture, it will be
necessary before removal to drill an approx. 25 mm dia. hole in the
sidewall of the tyre. Drain sealing compound from this hole and dispose
of this compound in an environmentally responsible manner. Clean the
disc wheel after removing the tyre.
Tyre removal with a fitting machine:

Unscrew valve insert, discharge air, force off tyre bead from rim flange
with pressing-off horn of device on outside and inside.
If tyre beads are stuck, first release the tyre with the pressing-off horn at
several points of the wheel before actually pressing off, apply tyre
mounting paste between tyre and rim flange and press off the tyres
completely.
Pull off balance weights on rim and clean rim to remove large pieces of
dirt.
Clamp wheel on mounting machine.
Narrow rim shoulder always faces upwards.
Important!
Vehicles with RDC:
To prevent the pressing-off horn from damaging the RDC wheel
electronics, do not rest the pressing-off horn on both rim sides in
the area of the valve.
Swing or fold mounting pillar into position and let it engage.

Adjust mounting head, pressing it on the rim edge fully, and turn down the
lever for the clamp; normally the distance of the mounting head will set in
automatically.
The valve must be approx. 15 cm to the right of the assembly head so as
to prevent the tyre iron from damaging the RDC wheel electronics.
Raise tyre bead with tyre iron over mounting finger.
Note:
On aluminum rims, it is best to use a tyre iron coated (either fully or
partially) with shrink-on plastic tubing to prevent damage.
Let fitting machine run back a short distance (counterclockwise) so that

tyre bead can slide fully onto mounting finger.
Then let fitting machine run forward in stages (clockwise).
In so doing, always check whether the lower bead is fully resting in the
well and allow the tyre time to move.
If the bead clamps, stop the machine and let it run back slightly.
If the upper bead is pulled off the rim, also lift the bottom bead over the
mounting finger with the tyre iron.
Let machine run back a short distance again and then forward (clockwise)
briefly until there is complete separation of the tyre from the rim.
Important!
Vehicles with RDC:
Tyre bead must not press onto RDC wheel electronics.
Release lock and tilt back or swing away mounting pillar.

Unclamp and clean rim.
Replace valve.
Coat rim flange and tyre beads with mounting paste (refer to BMW Parts
Service).
Important!
Vehicles with RDC:
When the wheel electronics are installed, the rim must not be
cleaned with high-pressure cleaning equipment.
Visually inspect wheel electronics for external damage and check
for tight fit; do not retighten screw and union nut. If valve parts are
loose, the complete valve must be replaced.
Keep wheel electronics free of tyre mounting paste.
Clamp rim on fitting machine, valve must be located at 180° to mounting

head.
Slide on tyre with lower bead partially over rim flange.
Swing or tilt mounting pillar into position and lock.

Check adjustment of mounting finger, readjusting if necessary, and
clamp.
Press tyre under mounting finger by hand.
Tyre bead must seat in rollers next to mounting finger.
Let fitting machine run forward (clockwise) a short distance.
Lower tyre bead will drop into well.
Important!
Vehicles with RDC:
Mount lower tyre bead so that no pressure forces are exerted on
RDC wheel electronics.
Turn wheel again into fitting position so that valve is at 180° to mounting
head.
Press upper tyre bead under mounting finger. Bead must seat in rollers
next to mounting finger.
Important!
Do not pinch or damage bead.
Operate fitting machine forwards (clockwise) little by little; while doing so,
make sure the lower tyre bead remains in the well.
Important!
Vehicles with RDC:
Mount upper tyre bead so that no pressure forces are exerted on
RDC wheel electronics.
After mounting, first release clamps and then inflate tyre (without valve).
Increase pressure up to 3.3 bar (330 kPa) in steps (jumping pressure).
If the tyre bead does not slip on all round at the rim edge, do not
increase pressure further but rather drain off air.
Press off tyre bead again, coat rim flange again with tyre mounting paste,
refer to BMW Parts Service, and pump up again to 3.3 bar. When the
beads are resting properly on the rim shoulders, increase inflation
pressure to max. 4.0 bar to ”settle” the tyre.
Screw in valve insert and correct tyre pressure.
General:

36 13 Subsequent installation of wheel-bolt lock
Loosen wheel bolts.

Lift car until wheel can be turned.
Loosen wheel bolts enough for it to be easy to move wheel on wheel
hub.
Turn wheel so that valve is face down.
Remove upper wheel bolt and insert wheel-bolt lock.
Possible play in wheel centre and wheel weight could cause imbalance.
This imbalance is reduced to a minimum by installing the somewhat
heavier wheel-bolt lock in the top wheel-bolt position.
Tighten wheel bolts crosswise and by hand in this position (wheel-bolt
lock at top, valve at bottom).
Lower car and tighten wheel bolts crosswise.
For tightening torque,
Should a customer complain about wheel imbalance after installation of
wheel-bolt lock, wheels will have to be finish-balanced.
General:

Headaches
Dizziness
Stomach aches
Vomiting
Diarrhoea
Cramps/fits
Unconsciousness

or mugs)
First aid measures:

immediately.
Danger of injury!
Impaired sight

First aid measures:

Warning!
Recycling:

ground.
37 14 511 Replacing front ride level sensor
Caution!
After assembly, check headlight adjustment.
Pull off connectors.

Unfasten nut (1) and disconnect control rod.
Release screws (2) and remove ride level sensor.
Installation:
Tightening torque, nut (1): 37 14 7AZ
Tightening torque, screws (2): 37 14 6AZ
37 14 512 Replacing rear ride-height sensor
Important!
After installation:
Check headlight adjustment, correct if necessary

Release nut (3) and disengage jointed rod from sensor lever (4).
Release screws (1) and remove ride-height sensor.
41 00 ... 0 Contents of Body, General
Before beginning - Checking the body for damage (e.g.
repair work following an accident)
General notes - Quality standard - Workshop equipment

Safety regulations - Safety at work - Information on hazards
- Information on vehicle protection
Material/new part - Materials science
- Expendable materials
Handling - Electrical system, electronics and optical - Vehicles with hybrid/electric drive
components fibre
- Flood damage
- Passive safety - Seats/seat belts
- Chassis and suspension and steering - Wheel rim repairs
- Retractable hardtop - Headlight repairs
Cavity sealing - Installation of shaped parts
- Position of shaped parts
Vehicle identification - General notes
number
Repair method - Repair stage 1a BMW/MINI/BMW i
Replacement of screwed-on
components
- Repair stage 1b BMW/MINI/BMW i

Repairs to outer skin
- Repair stage 2 BMW/MINI

Bonding and riveting
Welding using a MAG welder
without straightening bench
BMW i
Repairs to life module
Repairs to drive module
without straightening bench
- Repair stage 3 BMW/MINI

Bonding and riveting
Welding using a spot welding
system
with a straightening bench
BMW i
Repairs to life module
Repairs to drive module
with a straightening bench
Corrosion protection - General notes

Paint - General notes
- Information / warning labels

41 ... 0 Notes on the repair technique used in the main group 41
Two different repair techniques are used in body repair.
These are welding and bonding/riveting.
If the repair instructions do not specify a repair technique, then welding must always be used.
The bonding/riveting repair technique is always described in detail in the repair instructions.
Quality standards must be met.
41 00 ... Arranging shaped parts for cavity bulkhead
To reduce interior noise, certain areas of the body can have the cavities sealed. To do this, shaped parts are
inserted in the cavities. The shaped parts expand to fit the contact faces perfectly by heating the body to
approx. 180 Â°C and holding the temperature for approx. 20 minutes.
Since it is not possible during body repairs to heat the body up and maintain it at temperature for long enough,
the following procedure has been defined for this eventuality.
This procedure is described in
Installation of shaped parts for cavity bulkheads, except for side member cover
Installing cavity bulkhead cover for side member
Installation of a cavity bulkhead with cavity foam
.
Location of shaped parts for cavity bulkhead in E46 Saloon/Sedan
Location of shaped parts is marked by points.

(1) A-pillar,
refer to 41 00 ...
Installing shaped parts for cavity bulkheads, except for cover for side member
(2) Cowl panel, side
refer to 41 00 ...
(3) Roof frame, inner front and rear,
refer to 41 00 ...
(4) Roof frame, center front,
refer to 41 00 ...
(5) Roof frame, center rear,
refer to 41 00 ...
(6) C-pillar, inner,
refer to 41 00 ...

(7) C-pillar, outer,
refer to 41 00 ...
(8) Entrance, rear,
refer to 41 00 ...
(9) Entrance, center outer,
Spare part already in expanded form
Entrance, center inner,
refer to 41 00 ...
(10) B-pillar, outer,
B-pillar, inner,
refer to 41 00 ...
(11) Entrance, front,
refer to 41 00 ...
(12) Reinforcement, engine support, rear,
refer to 41 00 ...
41 00 ... Basic comments on handling aluminium components
In the following section, the main differences between aluminium and steel are itemised and notes on work
safety are provided.
1.0 Mounting
Special measures Reason

Store aluminium components in dry situation, and always store In damp atmosphere and in contact with
separately, or isolated from, steel components. steel, contact corrosion occurs.
Do not damage protective surface layer since this would cause Tendency for contact corrosion and paint
oxidation. migration.
Extra work involved in painting.
Restricted storage life.
1.1 Properties of aluminium
Comparisons with steel Effects

Aluminium parts are non-magnetic and by up to 50 % Aluminium components are easy to distinguish
lighter. from steel parts by using a magnet.
The electrical conductivity is almost 4 times higher. All electrical welding operations require higher
currents and therefore more advanced
equipment.
The elasticity module is only 1/3 as high. Convertibility is limited in comparison with steel.
Elongation failure is approx. 50 % slighter. When the material is stretched, cold
strengthening, restriction of plate thickness and
increased tendency to crack result.
Heat conductivity is 3 times higher, expansion is 2 times Heat dissipates more rapidly and the material
higher. expands more markedly.
At temperatures of between 200 °C and 250 °C, Strength is reduced, elongation characteristics
convertibility of the material is improved, but the original are improved.
properties of the material are altered at the same time
Aluminium shows no thrust traces, the melting point is 650 The temperature can only be checked on the
°C. basis of paint discoloration, bulging of the surface
and with the help of thermocouple pins.
1.2 Formation of corrosion
Cause Effects
Through contact with materials with no special coating, e.g. copper, tin, This plating process causes
nickel, iron and zinc, a plating (galvanic) process can initiate when aluminium to be removed from the
moisture is introduced to the environment. joint. Holes appear (corrosion).
Spare parts and accessories approved by BMW AG for aluminium Contact corrosion takes place.
manufacture (screws, washers, nuts, sealing materials etc.) are all Note:
subjected to a special form of surface treatment.
Damage which occurs
Damaged parts loose their protective coating. through contact corrosion is
not included in the warranty.
A special tool kit is required for working with aluminium. This gives rise to contact corrosion
and holes can appear as a result.
Materials also used for work on steel components can implant steel
particles in the softer surface of an aluminium component.
Brass and copper-based tools aggravate the formation of these
elements.
The use of liquid compounds attacks the surface. Risk of corrosion from chemical
factors.
1.3 Work safety/safety precautions
Risks Cautionary notes/specifications

There is a danger of explosion with fine Refer to BMW-special tool Workshop Equipment.
aluminium dust in particular concentrations
and quantities.
Fine aluminium dust impairs health Note national regulations.
(respiratory diseases).
In addition, comply with relevant regulations of UVV and BG
(in Germany).
During grinding work, always work with tools with integrated
suction facilities.
Grinding through coated parts to the base Use approved Explosive-Proof suction equipment.
material and grinding away large areas of the
surface of uncoated parts generates a high If the same suction equipment is also used when working on
concentration of fine aluminium dust. steel components, clean/empty any aluminium from the
system before and after each operation, and even in the
If this dust comes into contact with a naked course of an operation if a great deal of dust is created.
flame, an explosion can result.
Spontaneous combustion possible if the Do not allow fire sources of this kind to enter the vicinity of
suction system draws in combustible items suction equipment.
such as glowing chips from materials which
produce sparks, cigarettes etc. Danger of explosion!
When cleaning work surfaces before and No not use compressed air!
after working with aluminium - a vital
requirement - do not allow dust to swirl up.
41 00 ... Blind rivet
1.0 Recommended tools and equipment
Blind riveting tongs
Rivet head extension
Sourcing reference BMW Workshop equipment catalogue
Setting blind rivets:
Refer to repair instructions for rivet size.
Position bore holes for blind rivets in accordance with specification in repair instructions. If necessary,
carry over the positions of the blind rivets to the new part.
Drill holes that exceed the outer diameter of the blind rivet (example ∅ 4.2 mm with 4 mm blind rivet and ∅
6.8 mm with 6.5 mm blind rivet).
The edge of the hole must even on both sides.If necessary, sand down and even out surfaces (e.g.
edges of punch rivet connections).Deburr bore holes.
Apply adhesive.
Insert blind rivet. If necessary, remove adhesive that has emerged.
Position blind rivet tool vertically. Use rivet head extension if accessibility is poor.
Rivet blind rivet with blind rivet tool. In the meantime clean rivet head if dirty with adhesive. Risk of damage
to rivet head by penetrating adhesive.
Seal blind rivet with sealantD1 (risk of corrosion).
Seal cavities after work on vehicle paintwork on with cavity preservation (risk of corrosion).
41 00 ... Bonding on painted/primed surfaces
Attention!
These repair instructions apply only to components of the outer skin and not to structural
components.
These include roof outer skin, tail panel, rear side panels and components of the luggage
compartment floor.
Follow the vehicle-specific repair instructions.
Only the repair method described there must be used!
Conform with safety regulations !
Overview of topics:
1. Equipment
2. Expiry date of consumables
3. Preparation of surface
4. Bonding coat
5. Hardening times
6. Subsequent treatment
7. Disposal of adhesive
.
1.0 Equipment
Cleaning agentR1
Cleaning agent R2
Adhesive K5
Cartridge gun
2.0 Expiry date of consumables:
Glue cartridge is marked with a date.
Do not use adhesive after this date.
3.0 Preparation of surface:
3.1 Preparation of the surface on the vehicle (series status):
Establish a level bonding surface (e.g. grinding).
Do not sand primed bonding surfaces.
If the bonding surface is painted in the vehicle colour, the paint must be completely sanded off.
If necessary, pre-clean the bonding surfaces with cavity protection wax remover.
Clean bonding surfaces with cleaning agent R1.
Allow cleaned surfaces to dry for approx. 5 min.
Bonding surfaces must be completely dry.
3.2 Preparation of the surface on the vehicle (replacement of a bonded component):
Remove adhesive residue completely from vehicle. Remove all the existing reinforcement plates if
necessary (e. g. rear side panel).
Do not prime in the area of the bonding surfaces! Adhesive insufficiently bonds to primer.
If priming is needed after straightening work, cover the bonding surfaces.
If necessary, pre-clean bonding surfaces with cavity sealing wax remover.
Remove coarse dirt from the bonding surfaces using solvent cleaner R2.
3.3 Preparation of surface on new part:
Do not remove primer on new part.
Do not grind/sand bonding surfaces.
4.0 Adhesive application:
Processing temperature of glue cartridge 18 °C ‐ 30 °C.
Object temperature, vehicle and new parts, at least 15°C.
Do not use an air-powered cartridge gun.
Insert glue cartridge into cartridge gun, remove cap and allow both adhesive components to emerge.
Strip adhesive components uniformly and attach mixing tube.
Allow approx. 10 cm of mixed adhesive to emerge and then apply the mixed adhesive first on one side of
the bonding surface.
After applying the adhesive, check whether an adhesive component has emerged at the back of the glue
cartridge. If yes, break off the bonding procedure. Clean new part. Use new glue cartridge. Contact
national hotline.
Pot life of mixed adhesive approx. 2 h. A change of mixer is necessary only if no material has flowed
through the mixer for a period of 30 min.
Join components and secure in position.
Remove excess adhesive.
5.0 Hardening times:
Do not move the vehicle before the adhesive has hardened.
Check the degree of hardness of the adhesive with a fingernail.
If the adhesive cannot be pressed in any further with a fingernail, the vehicle may be moved (without
engine force) for further processing applications (e.g. painting).
Vehicle strength for driving applications is achieved after:
48 h at an object temperature of at least 15 °C (corresponds to approx. 18 °C room temperature).
Or 1 h in the spray booth (spray booth temperature 80 °C/object temperature 60 °C).
When using radiant heaters, make sure that the object temperature does not exceed 85 °C. Excessively
high temperatures will destroy the adhesive.
Remove contamination caused by adhesive residue immediately.
Hardened adhesive can only be removed mechanically.
6.0 Subsequent treatment:
Reseal areas which are cavity-sealed as standard.
7.0 Disposal of adhesive:
Hardened adhesive is disposed of as normal waste.
Empty glue cartridges are disposed of as normal waste.
Non-hardened adhesives and mixtures of adhesive and solvent and the like must be disposed of as
hazardous waste.
These regulations apply to the Federal Republic of Germany.
For other countries, comply with the (possibly differing) nationally applicable regulations.
41 00 ... Bonding steel on steel
Attention!
These repair instructions apply to structural components.
Such components include engine supports, A-pillars, B-pillars, etc.
Only use the repair procedures described there.
Conform with safety regulations!
Overview of topics:
1. Equipment
2. Preparing the surface
3. Bonding coat
4. Hardening times
5. Subsequent treatment
1.0 Equipment
Sandpaper
Cleaning agent R1
Cleaning agent R2
Adhesive K1
Cartridge gun
2.0 Preparing the surface:
Clean bonding surfaces using R1 solvent cleaner prior to sanding.
Remove paint from bonding surfaces using a wire brush or sandpaper with 120 graining.
Allow cleaned surfaces to dry for approx. 5 minutes.
3.0 Adhesive application:
Processing temperature of glue cartridge 18 °C ‐ 30 °C.
Object temperature, vehicle and new parts, min. 15°C.
cartridge. If yes, break off the bonding procedure. Clean new part. Use new glue cartridge. Contact
national hotline.
Join components and secure in position.
Remove excess adhesive. Do not use solvent cleaning agents.
4.0 Hardening times:
Refer to Notes regarding adhesive K1
5.0 Subsequent treatment of bonding surfaces:
Protect the repair area with cavity sealant.
41 00 ... Corrosion protection
Note:
Following repairs, the corrosion protection work already begins with the correct removal of the
underbody protection, anti-drumming layer and seam sealing in the repair area.
The products recommended by BMW are optimized with regard to corrosion protection.
1.0 Removing and applying sealant:

1.1 Removing sealant:
Important!
Do not burn off PVC material (sealant) with an autogenous torch or similar or heat to
temperatures above 180 °C. This would generate highly corrosive hydrochloric acid and release
harmful vapour.
The new sealant does not adhere appropriately to burnt polyvinyl chloride material and hence
subsequent rust creep is possible.
Remove PVC material with a rotating steel brush, or heat PVC to maximum 180 °C with a hot air blower and
scrape off with a spatula.
1.2 Applying sealant:
Prime and seal all weld seams that are sealed with sealant in original condition immediately after repair work.
Replace damaged or removed anti-drumming layers.
Note:
Required spray gun for sealant (order number 81 49 0 300 887).
Seal blind rivet with sealant (risk of corrosion).
Seal affected cavities with cavity preservation (risk of corrosion).
2.0 Basics of cavity preservation:
Apply cavity preservation after all body repairs.
Concluding cavity preservation is the most important part of all corrosion protection measures.
Use the cavity protection spray only for smaller-scale straightening work where the parts in question are easily
accessible. Use the pressure cup gun for all other repairs. Cavity protection agent is available in different
container sizes.
Use the relevant sensors with tubes for the different cavity areas.
Required tools can be found in the Aftersales Assistance Portal (ASAP) ‐ Service/Technology ‐ Workshop
Equipment (Start BMW) ‐ Shop Workshop Equipment or at www.bmwgroup‐wep.com.
Important!
Incorrectly performed cavity protection can, especially in the case of steel/aluminium joints, give rise
to a non-calculable product liability and safety risk.
The best repair is worth nothing if the subsequent cavity protection measures are not conscientiously carried
out.
2.1 Cavity preservation of steel parts:
New doors and lids must be sealed with cavity protection agent after being painted.
New sheet-metal parts or cavities, weld seams and folds formed by new sheet-metal parts must be sealed
with cavity protection agent after being painted.
The cavities affected must be sealed with cavity protection agent after all straightening work.
2.2 Cavity preservation of aluminium parts:
New doors, lids and side panels made of aluminium are not sealed with cavity protection agent.
After all straightening work on aluminium components, the cavities affected must be sealed with cavity
protection agent after being painted.
After all welding work (E52 only) on aluminium components, the cavities affected must be sealed with cavity
Cavities, seams and folds formed from new sheet metal parts or extruded profile must be sealed with cavity
41 00 ... EMC screws
(EMC = electromagnetic compatibility)
1. Purpose:
EMC screws are used in the bonding/riveting repair method to re-establish bonding transition.
They adopt the task of welded connections, which handle bonding transition between the individual
components in series production.
The punch or blind rivets used in the repair do not guarantee permanent bonding transition between the
individual components!
The EMC screws ensure the operational reliability and safety of the electrical/electronic components
following repairs!
2. Procedure for aluminium front end:
Each welded joint which is opened must be replaced by at least 2 EMC screws.
Position the 2 screws on the flange on which the weld seam has been separated. In the event of partial
replacement, position the screws in the area of the component overlap.
In the case of repairs using partial replacement, the number of EMC screws described in the repair
instructions must be fitted.
Drill holes to a diameter of 4.2 mm and insert screws.
Seal EMC screws with PU sealing material (risk of corrosion).
3. Procedure, steel body:
Install the number of EMC screws described in the repair instructions.
Drill holes to a diameter of 4.2 mm and insert screws.
Seal EMC screws with PU sealing material (risk of corrosion).
41 00 513 Fix bolts on the new part
Note: On BMW and MINI bodies, various welded and pushed in bolts
are being used.
Single ball/double ball (version 1):

Grind off any residues of the single ball (1), if applicable.
Drill hole with diameter 7 mm.
Set blind rivet nut (1).

Screw in single ball with thread until a height of 5 mm (double ball 10 mm)
is reached.

Clean area with solvent cleaner R1.
Clean bonding surface of repair element single ball (1) with solvent
cleaner R1.
Bond repair element optionally with adhesive K1, K5 or window pane
adhesive at the same position.
Coarse threaded bolt (version 1):
Grind off any residues of the coarse threaded bolt (1), if applicable.
Spot weld coarse threaded bolt to same position.

Set blind rivet coarse threaded bolt using riveting pliers.
41 00 ... Frame alignment control dimensions, body, side view, BMW E 46 4-
door / 2-door / Touring / Convertible
Dimensions in mm.
Tolerance: dimension over 1000 mm ± 2.0 mm.
Tolerance: dimension up to 1000 mm ± 1.0 mm.
Deviating dimension for 2-door in brackets, hinge dimensions not applicable to 2-door.
Dimensions for rear window aperture not applicable to Touring or Convertible
Note:
Only use the indicated values for a rough inspection.
Repairs can only be carried out correctly with the approved set of attachments and with straightening bench.
A Front impact absorber support, without attached front trim panel G Support for shock absorber, rear
B Front spring support K Top front hinge shaft
C Vehicle jack front take-up point L Lower front hinge shaft
D Vehicle jack rear take-up point M Top rear hinge shaft
N Lower rear hinge shaft
S Impact absorber support, rear
41 00 ... Frame alignment control dimensions, body, side view, front end,
BMW E 46 4-door / 2-door / Touring / Convertible
A Front impact absorber support, without attached front trim panel T Top front hinge shaft
B Front spring support U Lower front hinge shaft
C Vehicle jack front take-up point V Top rear hinge shaft
H Front axle mount, front W Lower rear hinge shaft
I Front axle mount, rear
Dimensions in mm.
Note:
41 00 ... Frame alignment control dimensions, body, side view, rear end, BMW
E 46 4-door / 2-door / Touring / Convertible
D Vehicle jack rear take-up point P Fixture, trailing arm, front

E Front axle mount, rear Q Fixture, trailing arm, rear
F Back rear axle support S Impact absorber support, rear
G Support for shock absorber, rear X Spring cup
Dimensions in mm.
Dimensions for rear window aperture not applicable to Touring or Convertible
Note:
41 00 ... Frame alignment control dimensions, body, top view, BMW E 46 4-
door / 2-door / Touring / Convertible
B Front spring support E Front axle mount, rear

H Front axle mount, front F Back rear axle support
G Support for shock absorber, rear
B - G = 3086 mm
H - E = 2609 mm
H - F = 3011 mm
Dimensions in mm.
Note:
41 00 ... Frame alignment control dimensions, body, top view, front end, BMW
A Front impact absorber support, without attached front trim panel J Arrangement, control arm, top
B Front spring support K Arrangement, control arm, bottom
H Front axle mount, front L Console for transmission support, M8 thread
I Front axle mount, rear M Engine support, rear (square bore)
Dimensions in mm.
Note:
41 00 ... Frame alignment control dimensions, body, top view, rear end, BMW
E Front axle mount, rear P Fixture, trailing arm, front

F Back rear axle support Q Fixture, trailing arm, rear
G Support for shock absorber, rear R Side member, rear ∅ 12 mm
N Mounting bracket for propeller shaft center mount S Impact absorber support, rear
O Console for transmission support, M8 thread X Spring cup
Dimensions in mm, tolerance ± 2.0 mm.

Note:
41 00 ... Gap dimensions on doors / engine hood and trunk lid
Lid seams 3.75 ± 0.75 mm.

Permitted parallelism deviation 1 mm.
Plane offset to relevant body section joining at back A = max. 1 mm
inwards.
Door seams:
Front side wall / front door = 4.25 ± 0.75 mm.
Front door / rear door = 4.5 mm ± 0.75 mm.
Rear door / rear side wall = 4 ± 0.75 mm.
Doors / sill = 5 ± 1 mm.
Permitted parallelism deviation 1 mm.
Vehicle section:
Area (a)
Turn signal indicator: side wall at engine hood to turn signal indicator, bottom
Transition from 3.3 mm to 1.5 mm ± 1 mm.
Area (b)
Headlight to engine hood: 5 mm
Area (c)
Engine hood: kidney on engine hood to headlight
Transition from 5.1 mm to 3.5 mm.
M - M:
(1) = Indicator light: side wall at engine hood to turn signal indicator, bottom
Transition from 3.3 mm to 1.5 mm ± 1 mm.
(2) = Headlight to engine hood: 5 mm
(3) = Engine hood: kidney on engine hood to headlight
Transition from 5.1 mm to 3.5 mm.
L - L:
a = 5 mm ± 1 mm
b = 3 mm ± 1 mm
c = 1,5 mm ± 0,5 mm
d = 5 mm ± 1 mm
N - N:
a = 5 mm ± 1 mm
O - O:
(1) = Rear lid
(2) = Side wall, rear
a = 0 ± 0.5 mm
b = 4,25 mm ± 1 mm
P - P:
(1) = Rear lid
(2) = Tail panel
Protrusion, rear lid/tail panel
a = 0,5 ± 0.5 mm
Gap, rear lid/tail panel
b = 6 ± 1 mm
41 00 ... General information about body repair
Body repair instructions are intended for qualified workers who work conscientiously and accept full
responsibility for their work.
The instructions are therefore limited to information and factory-approved repair procedures as well as
associated tips and data to make work easier.
Caution!
Bearing body parts, engine supports, pillars etc. with sharp-edged buckling which cannot be returned
to their original shape ”by means of cold straightening” must be replaced.
The described body repair jobs refer to complete or partial replacement of parts with original BMW parts or
sections of parts. Necessary straightening and dent removing work must be adapted to the concerned
damaged condition. Relevant welded and spot-welded seams must be inspected and repaired when
necessary.
The quantity and location of welded spots, inert-gas-welded seams and brazed connections can be taken from
the cut-out part. Use inert-gas-plug spot welding for spot-welded connections which are not easily accessible.
Most pictures were taken on an unfinished body shell. Remove or mask all vehicle components in the repair
area which could be damaged by heat, flying sparks and dust,
refer to instructions in MG 33.
In spite of continuous control over welding in standard production, there could be isolated cases of faulty
welding. Such welding will be subsequently repaired by inert-gas spot welding or 15 mm inert-gas-welded
seams on flange end in inaccessible zones. Consequently repaired welding seams on the body do not
necessarily indicate repairs carried out by a third party.
Example:
Left-hand engine carrier is resistance-spot welded - right-hand engine carrier is repaired with inert gas welding.
Caution!
Steering gear must be checked and, if necessary, replaced after an accident or driving conditions
similar to an accident,
refer to SI 32 01 88 (828).
All welded seams sealed off with body sealing compound in original state must be sealed off again thoroughly
immediately after repairing. Damaged anti-drumming compound must be replaced.
New sheet-metal parts or cavities, seams, cracks and folds formed by new sheet metal parts must be sealed
immediately with a body-sealing compound.
Disconnect negative lead at battery or at body support point,
Protect electric wires against damage and excessive heat.
Caution!
Disconnecting the vehicle battery will cancel the fault memories of control units.
Consequently always interrogate fault memories prior to disconnecting car's battery and have the
faults printed by the printer of the BMW Service Tester. Investigate stored faults.
Ignition must always be switched off before disconnecting or connecting control-unit connectors.
Removal and installation of components, relays, fuse, etc. could cause the storage of faults in fault memories
of control units capable of self-diagnosis. For this reason, fault memories must always be interrogated after
working on the electrical system.
Stored faults must be investigated and cancelled.
On vehicles with airbag systems, follow relevant instructions,
refer to MG 32 and MG 72.
Conform with fire and accident prevention regulations!
When welding while control units are installed, observe the following instructions:
Disconnect battery ground wire(s) and cover up negative terminal,
If welding is performed near the battery/batteries, remove it/them (flying sparks, combustion of explosive
gas),
Position return flow clamp of welding unit as close as possible to the welding point and establish a good
conducting link to the body (i.e. not on rubber mount or similar item), max. distance approx. 1 m,
Never use a ground pin at which wires have been secured as a ground point for a welding tool (if this is
the only point available, first remove all wires and protect thread with a nut).
Otherwise, especially for inert gas welding, watch for heat development (decision required on case-by-
case basis).
Vehicle with GPS Navigation System:
After welding work, recalibrate magnetic field sensor,
refer to Functional Description in DIS.
99 00 ... General instructions on paintwork
General instructions and classification of paint stages are described on the KSD CD (under Notes, General
information on flat rate unit data, Passenger car explanation for FRU specifications for paintwork).
The marked area shows the basis of area calculation for creating the flat rate unit. The marked area does not
show the area actually to be painted. If touching up is required, the painter defines the precise position as he
sees fit.
Special procedure for matte paintwork:
Matte paintwork cannot be touched up since the painted surface cannot be polished.
For further information, see also the BMW painting handbook and the Aftersales Assistance Portal.
51 14 ... General notes for labelling with adhesive films
In the event of a repair the adhesive films must be partially or completely replaced. The basic procedure for all
areas of the vehicle is described below.
In addition, vehicle-specific repair instructions are available.
1. Preparation:
Wash and dry vehicle. Rework with compressed air as required in area of joints.
Clean complete component surface with glass cleaner (BMW part number 83 12 0 396 775). Also clean the
inside of the component in areas, in which adhesive films are applied.
Only carry out repair work with clean hands!
Important!
Labels can only be applied to recently painted components after a waiting period of 2 weeks. The paint
hardening is only fully completed after this time.
2. Procedure for applying labels:
All adhesive films in the repair kit are marked with numbers. Prepare the required plastic films prior to start of
repairs.
The templates included in the repair kit assist orientation. A straight line running over the different components
is the top priority.
Pull off the templates positioning of the adhesive films.
Only throw away templates after completion of all repair work, as some templates are used several times.
Templates are always
applied along the light
edge (1). The light
edge is the reflection
of the light source in
radius (see arrow).
Roughly align the adhesive film using a template.

For large adhesive films, pull off the first 20 cm of protective film and fold back the edge.
Align and lightly press down the adhesive film. Use only one finger for this and not the entire hand so that air
pockets are unable to form under the adhesive film.
Pull off the remaining protective film and press down the adhesive film from front to rear and from inside to
outside.
If faults are made in applying the adhesive film, it can be pulled off and repositioned several times. When no
further corrections have to be made, use a squeegee to press down the adhesive film firmly from inside to
outside.
Lay protruding ends of the adhesive film around the component edge and press down firmly.
Carefully pull off
backing film (1) at an
acute angle.
41 00 ... General notes regarding bonding
Important!
.
The bonding surfaces must be kept free from contaminations of any kind. Avoid finger prints.
Cleanliness is top priority when bonding!
Cleaning agent: Cleaning agent R1
Expiry date of adhesive:
The glue cartridge is marked with a date.
Do not use the adhesive after this date.
Adhesive application 2K:
Insert glue cartridge in adhesive gun, remove cap and allow a small quantity of adhesive to emerge. Strip
adhesive components uniformly and attach mixing tube.
Allow approximately 1 mixer length of mixed adhesive to emerge (colour smears must no longer be
noticeable in the adhesive). Only then apply the mixed adhesive to one side of the bonding surface.
Disposal of adhesive:
hazardous waste.
41 00 ... Gluing of body components
For further information, refer to Gluing of steel components.
41 00 ... Grinding aluminium components
Grinding work on the outer skin:
To carry out grinding work by hand or machine, you must use the recommended tools and equipment
(refer to Service Information 5 03 03 975).
The workbay can be cleaned with conventional extractor systems (low dust concentration).
Grinding work on the structure (except Z8):
To carry out grinding work by hand or machine, you must use the recommended tools and equipment
(refer to Service Information 5 03 03 975).
The workbay can be cleaned with conventional extractor systems (low dust concentration).
Z 8 Spaceframe structure:
To carry out machine grinding on the structure, you must use the recommended device with grinding dust
extractor facility (refer to Service Information 5 01 00 532).
The workbay must be cleaned with the recommended explosion-proof extractor system (refer to Service
Information 5 01 00 532).
High dust concentration, explosion hazard!
2.0 Grinding outer skin and structure
Do not use any abrasives (grinding wheels, paper, etc.) which contain iron (risk of corrosion).
Always replace abrasives which have already been used to treat steel (risk of corrosion).
Use stainless steel wire brushes only (risk of corrosion).
Reduce speed of grinding machines. Excessive speeds cause a smearing effect.
Do not use coarse abrasive grains (only ≥ 80).
Do not grind notches into the material (risk of cracking).
Do not grind the material thin.
41 00 ... Grinding steel parts
Tools are recommended for manual grinding work.
Machines/equipment are recommended for machine grinding work.
See also Aftersales Assistance Portal (ASAP) - Service/Technology - Workshop Equipment (StartÂ BMW) -
Shop Workshop Equipment
2.0 Grinding outer shell and structure
Always replace abrasives which have already been used to treat aluminum (risk of corrosion).
Do not grind the material thin.
41 00 ... Handling airbags and restraint systems
1.0 Airbags and restraint systems
In the case of vehicles with airbags and restraint systems observe the relevant safety instructions.
When straightening work is carried out on the body there is a risk of airbags being accidentally activated
when the battery is connected.
Because of this risk the battery ground cable must be disconnected prior to all repair work on the body.
41 00 ... Handling electrical system and electronics
1.0 Battery
Explosion hazard in the vicinity of the battery during welding and grinding work. The battery must be
removed.
2.0 Control units
Control units with visible mechanical damages and/or electrical damages caused by accidents must be
replaced.
The following risks exist when the battery is connected:
Damage to control units resulting from welding work on the body or a line short circuit.
Accidental activation of airbags during straightening work on the body.
Because of these risks the ground cable must be disconnected prior to all repair work.
Control units are designed for a temperature of 65 °C. The temperatures in a spray booth do not pose
any problems. If a vehicle is in the spray booth at a displayed temperature of 80°C, the actual
temperature of the vehicle is ≤ 60 °C (object temperature).
Protect control units against the influence of heat >65 °C (e.g. during welding and drying work with infrared
beams or hot air blowers).
3.0 Electrical wires and wiring harnesses
Protect electrical wires and wiring harnesses against damage (e.g. during straightening and grinding work).
Protect electrical wiring and wiring harnesses against the influence of heat >65 °C (e.g. during welding and
drying work with infrared beams or hot air blowers).
Do not kink electrical wiring.
4.0 Optical fibres
Follow instructions for handling optical fibres.
41 00 ... Information on hazards
1. Aluminium
Hazards/effects Measures / regulations

Repair stage 1 and 2:
No hazards/effects none
Repair stage 3: (Welding - only E52)
Explosion hazard due to high concentration of fine aluminium Avoid high concentration of fine
dust. aluminium dust by means of
Arising e.g. during straight-through grinding of coated continuous extraction.
components in the base material and large-surface grinding of Use explosion-proof exhaust
bright-finish components. extraction unit
Explosion hazard due to swirling up of fine aluminium dust in Do not use compressed air when
cavities. cleaning the workbay.
Created by the necessary, thorough cleaning of machining
surfaces and tools before and after machining aluminium. Avoid swirling up dust when
cleaning the workbay.
Spontaneous combustion of fine aluminium dust when ignition Do not operate ignition and fire
and fire sources are drawn in. sources in the intake area of
E.g.: hot swarf, grinding sparks, cigarettes, etc. exhaust extraction unit.
2. Carbon
Hazards / effects Measures / regulations

Repair stage 1:
No hazards/effects none
Repair stage 2 and 3:
Explosion hazard due to high concentration of carbon Avoid high concentration of carbon dust
dust. by drawing it off continuously.
Produced when grinding carbon. Use explosion-proof exhaust extraction
Explosion hazard due to swirling up of carbon dust in unit
cavities. Do not use compressed air when
Created by the necessary, thorough cleaning of cleaning the workbay.
machining surfaces and tools before and after machining
carbon. Avoid swirling up dust when cleaning the
workbay.
Spontaneous combustion of carbon dust when ignition Do not operate ignition and fire sources
and fire sources are drawn in. in the intake area of exhaust extraction
E.g.: hot swarf, grinding sparks, cigarettes, etc. unit.
41 00 ... Information on metal filler
Note:
The metal spatula is omitted.
Changes to the procedure are described here.
equipment)
Warning!
Important!
direct sunlight.
Important!
Important!
fumes directly.
agent/paint.
cream.
Important!
First Aid:
Recycling:
41 00 ... Information on vehicle protection
Vehicle parts located in the repair zone or threatened by heat, sparks or dust, must be removed or
covered. For suitable covering material , see ServiceÂ Information.
Important!
Do not use flammable or dirty material for covering.
Missing or damaged labels (e.Â g. tyre pressure) must be replaced.
--> overview via the installation location
41 00 ... Installation of a cavity seal with cavity foam
Sourcing reference for cavity foam,

Caution!
The cavity foam may only be use for cavity sealing at the points at
which cavity sealing is present as standard!
The following repair represents the replacement of a shaped part for the
cavity seal by the use of cavity foam.
This type of cavity sealing is used at points at which shaped parts cannot
be used for repairs.
This is the case if great heat (e.g. by welding, soldering or tinning) has to
be applied in direct vicinity or at point of standard cavity seal after shaped
parts for cavity sealing have been fitted.
Here the installation of shaped parts for cavity sealing is not possible
due to the fire danger and possible damage to the structure of the
shaped part!
To replace shaped parts with cavity foam at further locations, adopt the
procedure shown here and adapt it to the relevant conditions.
It must be ensured that the cavity is completely sealed off.
Caution!
If cavities are connected to the outside area of the body and
complete sealing is not carried out, then penetrating moisture may
damage or destroy electrical components installed in cavities.
Note:
Check the accessibility for the spraying pipe of the cavity foam to
the affected cavity after removing the damaged part.
Location of shaped parts,

refer to arrangement of shaped parts in cavity seal
Further work,
refer to Installation of cavity seal for cover for side member,
refer to Installation of shaped parts for cavity seal, except for cover for
side member
Properties of cavity foam:
2K-PUR foam, solvent-free.
Excellent flow capacity, enabling complete sealing of cavities.
Good strength, preventing slipping in cavities.
Low water absorption, preventing corrosion.
Caution!
Observe processing instructions and safety precautions on the
spray can!
Use by date on can.
Do not use spray can after date marked on can, as then the
properties of the cavity foam no longer meet the requirements
of BMW AG.
Before application on the vehicle, it is advisable to fill a well
visible cavity of appropriate size with foam on an old part.
This enables an optimal dosage (i.e. spraying time) to be
specified for filling the cavity on the vehicle with foam.
Substrate must be
clean and free from
dust,
grease,
oil and stripping agent.
Note:
If vapors are produced when the foam is removed, these must
be extracted. Ensure the area is well ventilated.
Application temperature: 20 Â°C.
Tape off open passages to visible areas with adhesive tape to
prevent foam from escaping.
The foam can only be completely removed mechanically, even
when not completely hardened.
Application time after mixing: within 8 minutes.
Do not eat, drink or smoke during this operation.
Completely empty open can after use.
Cavity sealing of repair area is possible after a ventilation time
of 1 hour.
41 00 ... Installation solution for straight shank/hexagon rivet nut
Protection measures!
Wear safety goggles
Wear protective gloves
Hexagon/straight shank rivet nut (up to thread 8) with hand rivet gun
ZS308 Important!
Risk of damage!
Failure to comply with these instructions may result in the drill bit
slipping and causing significant paintwork damage.
1. Mark position of bore and then punch-mark component
Important!
If the determined drill bit diameter is not observed:
the knurling on the straight shank rivet nut is rendered useless
the component will be damaged when the straight shank rivet
nut is inserted
Determining suitable drill bit:

Depending on the rivet nut shank diameter, the next drill bit diameter
higher (5/10 step) can be used.
E.g. with a shank diameter of 10.1 mm, the 10.5 mm drill bit can be used.
The 11.0 mm drill bit must not be used.
2. Drill bore with determined drill bit and deburr, pilot-drill with a smaller
drill bit if necessary
3. Clean component, eliminate paintwork damage if necessary
Important!
To avoid corrosion, stop chips/swarf by means of cavity sealing.
Follow instructions on corrosion protection .
4. Preserving cavity
Important!
Follow manufacturer's operating instructions.
Make sure straight shank rivet nut correctly contacts component.
5Set rivet nut with hand rivet gunNote:

According to the manufacturer, the pictured tool is suitable up to an M8
thread (see Aftersales Assistance Portal (ASAP) ‐ Service/Technology ‐
Workshop Equipment (Start BMW) ‐ Workshop Equipment Shop or
www.bmwgroup‐wep.com).
Hexagon / straight shank rivet nut (up to thread M12) with hand rivet
gun MB512
Important!
Make sure hexagon rivet nut correctly contacts component.
Set rivet nut with hand rivet gun

Note:
41 00 ... Installing a cavity sealing with 2-component PU cavity foam
Sourcing reference for cavity foam HS1 (refer to BMW Parts Department).
Important!
The cavity foam may only be use for cavity sealing at the points at which cavity sealing is present as
standard!
The following repair represents the replacement of a shaped part for the cavity sealing by the use of cavity
foam.
This type of cavity sealing is used at points at which shaped parts cannot be used for repairs.
This is the case when large amounts of heat occur (e.g. due to welding, soldering or tin-plating) in the direct
vicinity or at the point of the standard cavity sealing.
It is not possible here to install shaped parts for the cavity sealing because of the fire risk!
To replace shaped parts with cavity foam at further locations, adopt the procedure shown here and adapt it to
the relevant ratios.
It must be ensured that the cavity sealing is fully completed.
Note:
Check the accessibility for the spraying pipe of the cavity foam to the affected cavity after removing
the defective parts.
Properties of cavity foam HS1:

2-component PU foam, solvent-free.
Ideal for use as insulating and sealing compound.
Information on dangers/hazards:
Avoid eye and skin contact.
Wear eye protection, solvent-resistant protective gloves and protective clothing.
Do not inhale.
Apply in well ventilated rooms only.
Warning!
Application time after mixing process: within 8 minutes!
Residual amounts which are not used can cause the can to explode on account of a chemical reaction
(buildup of heat)!
Alternatively, cool the can containing the non-removed residual amount for several hours in cold water.
Keep heat and ignition sources far away.
Read the manufacturer's information on hazards/dangers (printed on the can) prior to application.
Processing instructions:
Observe the expiry date on the cartridge.
Do not use spray can after the expiry date has passed. After the Use by date the properties of the cavity
foam will no longer meet the requirements of the BMW Group.
Cavity preservation of the repair area possible after an air drying time of 1 hour.
Surface must be clean, free of dust, grease, oil and separating agents.
Application temperature at least 15 °C. Optimally 20 °C.
Important!
Foam expands many times over as it sets (change in volume).
Before applying to the vehicle, fill a clearly visible cavity of corresponding size with foam on a used part.
This enables an optimal dosage (i.e. spraying time) to be specified for filling the cavity on the vehicle with
foam.
Tape off open passages to visible areas with adhesive tape to prevent foam from escaping.
The setting takes approx. 30 minutes. Mechanical processing (e.g. drilling, cutting, etc.) is then possible
Remove fresh, non-hardened polyurethane foam with adhesive remover 208.
Hardened polyurethane foam can only be removed mechanically.
Excess hardened polyurethane foam can be disposed of as residual waste.
Cans that are not entirely empty or are unused and have an expired expiry date are classed as
hazardous waste.
Observe the manufacturer's processing instructions (printed on the can).
41 00 ... Installing a cavity sealing with 2-component PU cavity foam
Sourcing reference for cavity foam HS3 (refer to BMW Group Parts).
Attention!
The cavity foam may only be use for cavity sealing at the points at which cavity sealing is present as
standard!
The following repair represents the replacement of a shaped part for the cavity sealing by the use of cavity
foam.
This type of cavity sealing is used at points at which shaped parts cannot be used for repairs.
This is the case when large amounts of heat occur (e.g. due to welding, soldering or tin-plating) in the direct
vicinity or at the point of the standard cavity sealing.
It is not possible here to install shaped parts for the cavity sealing because of the fire risk!
To replace shaped parts with cavity foam at further locations, adopt the procedure shown here and adapt it to
the relevant ratios.
It must be ensured that the cavity sealing is fully completed.
Note:
Check the accessibility for the spraying pipe of the cavity foam to the affected cavity after removing
the defective parts.
Properties of cavity foam HS3:

Ideal for use as insulating and sealing compound.
Wear eye protection, solvent-resistant protective gloves and protective clothing.
Do not inhale.
Warning!
Processing after the mixing process within a few seconds!
Keep heat and ignition sources far away.
Observe the manufacturer's information on dangers / hazards prior to application (imprint on double
cartridge).
Processing instructions:
Observe the expiry date on the cartridge.
Do not use cavity foam after the expiry date has passed. After the Use by date the properties of the
cavity foam will no longer meet the requirements of the BMW Group.
Surface must be clean, free of dust, grease, oil and separating agents.
Attention!
Foam expands during hardening (volume change).
Tape off open passages to visible areas with adhesive tape to prevent foam from escaping.
The setting takes approx. 30 minutes. Mechanical processing (e.g. drilling, cutting, etc.) is then possible
Remove fresh, non-hardened polyurethane foam with adhesive remover 208.
Sourcing reference, see BMW Group Parts.
Hardened polyurethane foam can only be removed mechanically.
Excess hardened polyurethane foam can be disposed of as residual waste.
Double cartridges that are not entirely empty or are unused and have an expired expiry date are
classified as hazardous waste.
Observe the manufacturer's processing instructions (imprinted on double cartridge).
41 00 ... Installing cavity bulkhead cover for side member
The following repair represents replacement and installation of the cavity

bulkhead in the side member cover.
In this case, the shaped part is already expanded in the spare part.
refer to Arrangement of shaped parts in cavity bulkhead.
Further scopes,
refer to Installation of shaped parts, except for cover for side member,
refer to Installation of a cavity bulkhead with cavity foam.
Before this operation, the spare part to be fitted should be prepared
ready for installation (adjusted to fit, cut to size, coated with zinc dust
paint etc.).
Caution!
The open time of the original BMW window adhesive until a skin is
formed is 30 minutes in a standard climate of 23 Â°C and 50 %
relative humidity.
The open time of the adhesive until a skin is formed is determined
by the relative humidity.
The higher the humidity, the faster the adhesive hardens.
Note:
First clean contact faces of foam residue.
Caution!
If vapors are produced when the foam is removed, these must be
extracted. Ensure the area is well ventilated.
Caution!
Observe safety instructions when dealing with
activator for original BMW windshield adhesive, refer to BMW
Parts Service
original BMW windshield adhesive, refer to BMW Parts Service
.
Cover for front side member:
Apply an approx. 15 mm high bead of original BMW windshield adhesive
on the contact surface of the already expanded foam insert (1).
Caution!
Do not coat the area for plug welding (2) with original BMW
windshield adhesive!
Burn hazard!
Apply as little heat as possible during plug welding to prevent the

adhesive coat from being damaged.
Cover for rear side member:

Caution!
Burn hazard!

Lightly sand the contact surface of the front and rear expanded foam
insert of the side member cover with coarse sandpaper (50 - 100 grain).
Clean the contact surface of the front and rear expanded foam part with
activator for original BMW windshield adhesive.
Clean contact surface of the front and rear expanded foam part on the
body with activator for original BMW windshield adhesive.
Fit, secure and weld up spare part.
41 00 ... Installing cavity sealing (expanded)
Note:
Carry over schematic diagram to the relevant vehicle type.
The following repair represents the procedure for an already expanded

cavity acoustic baffle.
The cavity acoustic baffle remains on the body in this instance.
Before these work steps, prepare the new part so that it is ready to
install (adapting, cutting to size, applying welding primer etc.).
Clean contact surface (1) with cleaning agent R2.

Apply a bead (2) approx. 15 mm high of sealant D2 to contact surface (1).
If necessary apply sealant D2 somewhat thinner on each side, to
prevent the sealant from running.
Fit, secure and weld up new part.
Warning:
Ensure adequate ventilation over entire processing period.
41 00 ... Installing cavity sealing (not expanded)
Note:
Carry over schematic diagram to the relevant vehicle type.
The following repair represents replacement of a cavity acoustic baffle.

Before these work steps, prepare the new part so that it is ready to
install (adapting, cutting to size, applying welding primer etc.).
Sand contact surface of cavity acoustic baffle (1) with coarse-grained

sandpaper (grain 50-100).
Clean contact surface (1) with cleaning agent R2.
Apply a bead approx. 15 mm high of sealant D2 to contact surface (1).
If necessary apply sealant D2 somewhat thinner on each side, to
prevent the sealant from running.
Attach cavity acoustic baffle in specified position (see old part).
Fit, secure and weld up new part.
Warning:
Ensure adequate ventilation over entire processing period.
41 00 ... Installing shaped parts for cavity bulkheads, except for cover for
side member
The following repair represents replacement and installation of a shaped

part for the cavity bulkhead of the C-pillar.
When replacing shaped parts in other locations, adopt the procedure
illustrated here and adapt to suit prevailing conditions.
refer to arrangement of shaped parts in cavity bulkhead.
Further scopes,
refer to Installation of cavity bulkhead for cover for side member,
paint etc.).
Caution!
relative humidity.
Note:
Caution!
Caution!
Parts Service
.
Shaped parts with clips:Caution!
If clips are fitted to shaped parts to secure them, do not allow clips
to engage.
Fit shaped part and mark up contact face on body and spare part,
fitting spare part if necessary.
Shaped parts with bore for retaining tabs:

Fit shaped part and allow retaining tabs to locate in bores.
Mark up contact face on body and spare part, fitting spare part if
necessary.
If necessary, remove spare part once again.

Remove shaped part.
Surface-sand flanging surfaces of shaped part with coarse sandpaper (50
- 100 grain).
Clean contact surfaces on the body and on the shaped part with
Apply an adhesive bead of original BMW windshield adhesive approx. 15

mm high within the marked contact surface of the shaped part.
Locate shaped part.
Shaped parts with clips:
If locating clips are fitted to shaped part, allow clips to engage.
Shaped part with bore:

If the shaped part has bores for retaining tabs, allow bores in retaining
tabs to engage in retaining tabs.

After locating the shaped part, ensure that bores for retaining clips are
sealed and, if necessary, reseal them.

After locating the shaped part, ensure that recesses on retaining tabs
are sealed and, if necessary, reseal them.
on the contact surface of the shaped part.
Caution!
Increase height of glue bead to min. 20 mm at edges (1, 2) and
other critical sealing points.

41 00 ... Materials science
1. Aluminium
1.1 Chassis/suspension components
Read and observe the Notes on chassis/suspension components before handling aluminium.
1.2 Material influences
Causes Effects / remedies
A galvanic element is created under the This plating process causes aluminium to be removed from
effects of moisture by contact with materials the connection point.
such as copper, tin, nickel, iron and zinc.
This results in surface corrosion or pitting.
New parts and accessory parts which have been approved
by the BMW Group for aluminium (screws, washers, nuts
etc.) have undergone special surface treatment.
Such parts must not be replaced by conventional parts.
Note:
Damaged parts lose this protection and must be
specially coated or replaced.
Damage caused by contact corrosion is excluded
from the warranty.
Tools also used for work on steel Surface corrosion or pitting occurs.
components can implant steel particles in the
softer surface of an aluminium component. A separate tool set is available for processing/machining
aluminium.
Surfaces are attacked when fluxing agents Soldering is not permitted for joining aluminium components.
are used.
Risk of corrosion from chemical factors.
Aluminium/steel grinding dust from adjoining This results in surface corrosion.

working areas.
Erection of protective barriers.
1.3 Machining properties
Properties of aluminium Effects

compared with steel
Aluminium parts are Attachment with magnetic tools/working aids is not possible.
magnetically neutral.
Elasticity is only 1/3 as Convertibility is limited in comparison with steel.

high.
Overstretching the material results in strain-hardening and an increased tendency
Elongation failure is of cracking.
approx. 50 % slighter.
Electrical conductivity is Electric welding methods require different equipment (MIG welding).
almost 4 times higher.
Material expansion The material expands more markedly. Shorter heat treatment is necessary for
during heating is twice as removing dents.
high.
Thermal conductivity is 3 Heat is drained more quickly. Adjoining working areas are affected more heavily
times higher. e.g. during welding.
Structural transformation Elongation characteristics and thus plasticity are improved.

between 200 °C and
250 °C Strength is reduced.
Important!
No heat treatment during repair work on the vehicle structure! Workshop
operation doesn't make it possible to control the temperature to
sufficiently exact levels.
Aluminium shows no The melting point is 650 °C. Once the melting temperature has been reached, the
annealing colours. material begins to flow without any further indications.
The temperature can only be estimated by means of the paint colouring and the
surface warpage.
Important!
Do not use thermo crayons. Not suitable for workshop operation because
the paint runs too quickly.
1.4 Storage
Characteristic features of aluminium Special measures

Corrosion (ageing) in damp environments. Store aluminium components in a dry place.
Contact corrosion in event of contact e.g. with Always store aluminium components separately or in
steel components. isolation from steel components.
Susceptibility to paint infiltration. Do not damage factory protective layer of the surface since
this would cause oxidation.
Failure to comply with this requirement would result in more
painting work.
Situation:
Procedure:
C. Fire damage
Wishbones
Front axle support
Pitman arms
Track rods
Steering column
Note:
Appendix 1.

great effort.
1. Open ELV
Note:
1
Attention!
41 00 ... Notes on adhesive K1
Important!
Note the following information before starting to apply adhesive!
Country-specific safety and industrial safety regulations
Processing instructions on glue cartridge
Storage:
Dry at 15°- 25 °C.
Shelf life:
Surface pre-treatment:
The pre-treatment depends on the material to be bonded and its coating.
Required cartridge gun:
Overview of glue cartridge guns
Do not use compressed-air-operated cartridge guns!
Preparing the glue cartridge:
Opened glue cartridges may be used again before the expiry date as long as a new mixing tube is used.
The working temperature of glue cartridge must be at least 20°C.
Insert glue cartridge into cartridge gun, remove cap and allow both adhesive components to emerge. Strip
adhesive components uniformly and attach mixing tube. Only use mixing tubes supplied with glue cartridge.
Allow approx. 10 cm of mixed adhesive to emerge.
Only after this apply the mixed adhesive to one side of the bonding surface.
Application time of mixed adhesive approx. 2 hours. A change of mixer is only necessary if over a period of
1 hour no material has flowed through the mixer.
2-component adhesive application:
Read the vehicle-specific repair instructions to determine the thickness and positioning of the adhesive bead.
cartridge. If yes, break off the bonding procedure. Clean new part. Use new glue cartridge. Contact national
hotline.
Hardening time:
If the adhesive cannot be pressed in any further with a fingernail, the vehicle may be moved (without engine
force) for further processing applications (e.g. painting).
48 hours at an object temperature of 15°C.
1 hour at an object temperature of 60°C.
0.5 hours at an object temperature of 85°C.
Important!
When using radiant heaters, make sure that the object temperature does not exceed 85 °C.
Excessively high temperatures will destroy the adhesive.
Non-hardened adhesives and a mixture of adhesive and solvent and the like must be disposed of as
hazardous waste.
Important!
Storage:
Dry, at 15 °C - 25 °C.
Shelf life:
Refer to vehicle-specific repair instructions or Notes.
Cartridge gun 81 49 2 355 475 for 2x290 ml container
Preparation of the glue cartridge (2x290 ml):

Application time of adhesive at 28 °C 35 min and at 18 °C 50 min
Remove the sealing cap on the back of the glue cartridge. Remove the safety and connecting pipe. Puncture
the glue cartridges open. Attach the connecting pipe and insert the glue cartridge in the cartridge gun. Allow
both adhesive components to emerge. Strip adhesive components uniformly and attach mixing tube. Only use
mixing tubes supplied with glue cartridge. Allow approx. 10 cm of mixed adhesive to emerge.
Only after this apply the mixed adhesive to one side of the bonding surface.
hotline.
Hardening time:
The following hardening times apply unless the specifications in the vehicle-specific repair instructions indicate
otherwise:
Adhesive K2 (2x290 ml):
Important!
During the initial 12 hours, no accelerated hardening with a heat gun or heat chamber is permitted!
The solidity for installation work on the vehicle is reached after:

Important!
When a complete side frame is replaced (without partial replacement), the hardening period will
increase to 24 hours until the beginning of installation work.
hazardous waste.
Important!
Storage:
Dry at 15°- 25 °C.
Shelf life:
See vehicle-specific repair instructions
Do not prepare the glue cartridge until just before applying the adhesive.
Pot life of adhesive is approx. 10 minutes at 25 °C.
Before starting to apply adhesive, allow approx. 1 mixing tube length of mixed adhesive to emerge. Only then
apply the mixed adhesive to one side of the bonding surface.
Opened cartridges may be used again before the expiry date as long as a new mixing tube is used.
Hardening time:
Adhesive disposal:
hazardous waste.
Important!
Storage:
Dry at 15°- 25 °C.
Shelf life:
Working life of adhesive is approx. 10 minutes.
Before starting to apply adhesive, allow approx. one half mixing tube length of mixed adhesive to emerge. Only
then apply the mixed adhesive to one side of the bonding surface.
Hardening time:
The bonded connection will be resistant after 30 minutes.
hazardous waste.
Important!
Storage:
Dry at 15°- 32 °C.
Shelf life:
Pot life of adhesive is approx. 60 minutes at 23°C.
hotline.
Hardening time:
If the adhesive cannot be pressed in any further with a fingernail, the vehicle may be moved (without engine
force) for further processing applications (e.g. painting).
1 hour at an object temperature of 60°C.
0.5 hours at an object temperature of 85°C.
Important!
When using radiant heaters, make sure that the object temperature does not exceed 85 °C.
Excessively high temperatures will destroy the adhesive.
hazardous waste.
Important!
Storage:
Dry at 15°-25 °C.
Shelf life:
Pot life of adhesive is approx. 10 minutes at 25 °C.
Opened cartridges may be used again before the expiry date as long as a new mixing tube is used.
Hardening time:
hazardous waste.
41 00 ... Notes on aluminum driveline components
refer to 33 00 ...
41 00 ... Notes on cleaning agent R1
Use only cleaning agent R1, as other cleaning agents cab be emollient/moistening or may start to dissolve the
cathodic dip paint primer.
Warning!
damage.
Attention!
agents !
Warning!

Suitable gloves
Apron
Rubber boots
Ear protectors
Safety shoes
Attention!
engine
washes.
tyre valves.
Attention!
Important!
Install Helicoil thread inserts so that they are flush with the original thread.
Note:
Damaged threads may be repaired with Helicoil thread inserts. Comply with the procedure described in
the example.
Screw connection Vehicle Bolting Helicoil thread

point(s) insert
Front axle support to engine support E46 All M12x1.5x18
E53 All M12x1.5x18
E60, E61, E63, E64 Front, middle See repair elements
Rear M12x1.5x18
E65, E66, E67 All M12x1.5x18
E70, E71, E72 All M14x1.5x21
E83 All M12x1.5x18
E85, E84, E86, E89 All M12x1.5x18
E81, E82, E87, E88 All M12x1.5x18
E90, E91, E92, E93 All M12x1.5x18
E92 with S65 All M10x1.5x15
Bracket, wishbone, to engine support E46, E85, E86, E89 All M10x1.5x15
Rear axle support to side member E46 All M12x1.5x18
E53 All M14x1.5x21
E60, E61 All M14x1.5x21
E63, E64 All M14x1.5x21
E65, E66, E67 All M14x1.5x21
E70, E71, E72 All M14x1.5x21
E83 All M12x1.5x18
E84, E85, E86, E89 All M12x1.5x18
E81, E82, E87, E88 All M12x1.5x18
E90, E91, E92, E93 All M12x1.5x18
Bearing support, trailing arm to side E46, E83, E85, E86, All M12x1.5x18
member E89
41 00 ... Notes on repairs of aluminium parts
The repair of aluminium components is comparable to the repair of steel ones.
Due to the design-related increase in panel thickness of 1.2 ... 1.4 times relative to steel, the material is
convenient to handle and work with.
In the following section, attention is drawn to the differences involved in working with aluminium and steel.
2.0 Parts identification
Material can be identified clearly by using a magnet.
Note:
In addition, the Service Information bulletins draw attention to differences.
Externally, there is virtually no way to distinguish aluminium parts of a vehicle from steel parts.
2.1 Finishing
Special tools should be used for finishing operations.
Always clean tools contaminated with metal particles.
Refer to the relevant section of the Repair Instructionsfor information about the finishing of components.
2.2 Knocking out dents

Work with wood, aluminium and plastic hammers. Avoid elongation and
cracking.
Note:
Do not use tools with sharp edges.
Press out dents from behind center of dent and smooth with gentle blows from Avoid material buildup.
behind.
Note:
With slight, small dents (e.g. hail damage) this is possible without damage to the
paintwork.
When reshaping pointed, sharp-edged dents, only apply heat to severely Avoid local compaction
distorted areas (gas burner). and excessive elongation.
Note:
From just 200 °C (slight brown discoloration of paint surface), desired level of
convertibility is reached.
Do not heat or overheat large areas! Avoid irreparable damage
to the component
On uncoated panels, insert thermocouple pins to check temperature at a (distortion).
distance of two finger-widths from the flame.
Draw in protruding material at 150 °C...200 °C.
Note:
With dents which can only be accessed from outside, no procedure can at
present be recommended. In this event, if cracking occurs, the component must
be replaced.
2.3 Replace

Always work with suction. Danger of explosion!
Always replace grinding wheels when machining steel. Risk of corrosion!

Replace steel wire brushes with stainless steel wire brushes.
Reduce motor speed of grinding tools and replace scrubber discs with surface Material surface heats
grinder discs. up too much.
Machine away paint residue and oxidised areas: only use abrasive paper approved Effect of lubrication.
for use with aluminium - grain size 80/100.
2.4 Paintwork
Clean surfaces with BMW silicone remover.
Surface treatment, preparation for painting and selection of paint products follows a similar procedure to steel.
For further instructions, please refer to BMW Paint Handbook/Paint Brochure.
41 00 ... Notes on the water drain hose of the slide/tilt sunroof
The water drain hoses for the slide/tilt sunroof are partially permanently integrated in the body and cannot be
replaced individually.
These water drain hoses can only be completely replaced with extensive body repair work (e. g. after an
accident).
Component Vehicle Individually replaceable

Water drain hose, front All BMW No
All MINI
Rear water drain hose E60, F34 No
All other BMWs Yes
All MINI Yes
An individual solution is required for damage that was not caused by an accident.
Contact national hotline.
99 Notes on using temperature-controlled infra-red radiators
When using temperature-controlled infrared radiators, damage to adhesive bonds, paint and vehicle
components can occur when drying spatula and filler.
The temperature sensors in the infrared radiator only operate reliably on large, even surfaces.
On small surfaces such as C-pillars or sills, often only a colder, adjacent area is measured.
This leads to actual surface temperatures of up to 130°C, even if only 70°C is set on the infrared radiator.
When the rear side walls are partially replaced by bonding and riveting, these high temperatures can lead to a
visible pattern in the area of the joint.
Remedy:
Check the surface temperatures on small component surfaces during the drying process with an external
temperature sensor.
The general rule is: The surface temperatures must not exceed 85°C.
Important!
Do not use infrared radiators on carbon parts!
Risk of component destruction.
41 00 ... Opening bonded connections
1. Opening spot-welded adhesive joint
Open welding spots.
Warning!
Draw off vapour and gases!
Use personal protective clothing/equipment.
Heat connecting flange with a hot air blower. Heat components to max. 250 °C object temperature.
Release connecting flange with chisel.
Remove adhesive residue from connecting flange.
2. Opening bonded connections

Release any punch rivet or blind rivet.
Roughly cut out damaged component.
Warning!
Draw off vapour and gases!
Use personal protective clothing/equipment.
Heat adhesive flange with a hot air blower. Heat components to max. 250 °C object temperature.
The component can be peeled with the aid of pliers. Do not damage adjacent components.
Remove adhesive residue from connecting flange.
3. Opening bonded connections on aluminium roofs

Procedure is described in detailed in the relevant repair instructions.
41 00 ... Opening brazed connections
The ”Bonding and Riveting” repair method involves replacing the watertight brazed connection with adhesive.
This gives rise to a new procedure for opening brazed connections.
Grind brazed seam with a belt grinder. This keeps the influence of heat in the area around the brazed seam as
small as possible.
Important!
Never use a gas flame.
All traces of brazing solder do not have to be removed.

Do not grind body panels thin.
41 00 ... Opening rivet connections
Different rivet types are used on BMW vehicles.
1. Opening blind rivets:
1.1 Loosening blind rivets (N1, N2, N7, N8, N9 and N10):
Grind off blind rivet head with a belt or angle grinder. Do not grind off base material. Remove rivet remnants with
a drift punch.
1.2 Opening blind rivets (N3 and N6):
Drill out blind rivet head with a 5 mm dia. drill bit. Do not damage base material. Remove rivet remnants with a
drift punch.
2. Opening punch rivets:
2.1 Opening punch rivets by extraction:
This procedure is used on the reduced-weight aluminium front end.
Recommended tools and equipment:
Stud welding apparatus (refer to Service Information 5 03 03 975) with gas bottle containing inert gas
(82 % argon, 18 % CO2).
Stainless steel stud (sourcing reference via BMW Parts Department image board Aluminium and
steel/bonding and welding)
Universal riveting tool (refer to Service Information 5 03 03 975)
Grind off paint and dark grey coating of punch rivets.
Position bolt centrally on the rivet and weld on vertically. The area in which the bolts are welded on should be
between the two grounding terminals. Position both terminals, if possible, on the top side of the panel on which
the rivet is located.
Extract bolt with welded-on rivet using universal riveting tool. Use a large plastic nose piece if not otherwise
specified in the repair instructions. Check plastic nose piece prior to use for wear.
Plastic nose piece must rest on sheet metal all round; if necessary, grind off plastic noise piece in collision
area.
Do not push riveting tool forcefully onto special-steel bolts.
Do not use riveting tool to bend special-steel bolts.
Pay particular attention to central positioning of the bolt when using the small plastic mouthpiece.
Follow the equipment manufacturer's instructions for use.
2.2 Opening punch rivets by drilling out:
Drill out rivets with a 6 mm dia. carbide drill bit.
Punch rivets can be drilled out on both sides. When drilling from the protruding rear side, spot-drill the rivet
shank only and remove the rest with a rivet punch.
Note:
Sand down and even out remaining burr on the rear side.Deburr bore holes.
Use a drift punch to remove punch rivet remnants in the aluminium (risk of corrosion).
Clean vehicle to remove swarfs (risk of corrosion).
41 00 ... Opening welded connections
1. Components made of steel:
1.1 Opening welding spots (resistance pressure spot welding):
Sheet steel panels made from high- and super-high-strength materials make great demands on the tools
used.
Only with special carbide milling cutters can welding spots be drilled out on these sheet panels.
Use BTR/BOR milling cutters only in conjunction with Vario Drill spot-weld remover. Sourcing reference for
spot-weld remover and BTR/BOR milling cutters, see Aftersales Assistance Portal (ASAP) ‐
Service/Technology ‐ Workshop Equipment (Start BMW) ‐ Shop Workshop Equipment or at www.bmwgroup‐
wep.com.
Procedure:
If necessary, surface-grind existing unevenness with a belt or angle grinder in the area around the welding
spot.
Set punch mark in centre of welding spot. Set 8 mm dia. welding spot drill bit on punch mark and drill
through top metal sheet.
Note: Because the welding spots may have surface-hardened, grind them if necessary with an angle
grinder and paper grinding disc.
Use a chisel to separate the sheet metal flange and remove the component.
Follow the special procedure for spot welds .
1.2 Opening MAG weld seams and MIG brazing seams:
Procedure:
Grind off weld seams with a belt or angle grinder. Do not grind the base material thin.
Use a chisel to separate the sheet metal flange and remove the component.
1.3 Opening laser weld seams:
Laser weld seams are used in the roof outer skin area.
Procedure:
Roughly cut roof outer skin in the roof channel to improve accessibility.
Place angle grinder with grinding disc on laser weld seam and grind through top metal sheet. Be careful
not to cut through and damage sheet metal underneath.
Remove sheet metal flange.
2. Components made of aluminium:
2.1 Opening MiG weld seams:
Procedure:
Grind off weld seams with a belt or angle grinder. Do not grind the base material thin.
Do not use a chisel.
Remove component.
41 00 ... Overview of adhesive cartridge guns
Adhesive gun 83 19 2 149 522

Obtainable via Electronic Parts Catalogue.
Usable for adhesives K4, K5a.
Usable for BMW 2K polyurethane foam.
Including insert 1:1 and 2:1.
Adhesive gun 81 49 0 443 166

Orderable via BMW Workshop Equipment Catalogue.
Usable for adhesive K3.
Adhesive cartridge gun 81 49 2 213 059

Usable for adhesives K1, K5b, sealant D1/D2, window glass adhesive
and all 310 ml Euro cartridges.

Usable for structural foam HS2.
Note:
Special tool number 41 3 010
Usable for adhesive K2 (2x290 ml glue cartridge)
1.0 Adhesives
Designation, repair Naming of Electronic Parts Part number of Electronic Parts Remarks
instructions Catalogue Catalogue
Adhesive K1 Body adhesive K1 83 19 0 413 015 195 ml
Adhesive K2 Body adhesive K2 83 19 2 355 849 2x290 ml
Adhesive K3 Body adhesive K3 83 19 0 417 144 2 x 300
ml
Adhesive K6 Adhesive set K6 83 19 2 317 925
1.1 Primer / activator
PrimerP1 PrimerP1 83 19 0 302 556 50 ml
PrimerP2 Primer P2/Gas cartridge 83 19 0 302 555 50 ml
Betawipe 4800 Betawipe 4800 83 19 2 357 707 10 ml
Bonding base VP 206 Bonding base VP 206 83 19 9 407 777 30 ml
Aktivator 205 Aktivator 205 83 19 0 030 155 250 ml
1.2 Cleaning agent
Filler S1 Alluvial tin replacement 83 19 2 464 575 175 ml
1.3 Fillers
Cleaning agent R1 Cleaning agent R1 83 19 2 211 217 125 ml
Cavity sealing wax Cavity sealing wax remover 83 12 0 390 086 500 ml
remover
2.0 Rivet
Designation, repair Naming of Electronic Part number of Electronic Remarks

Blind rivet N1 Blind rivet N1 83 19 0 301 414 dia. 6.5 mm; clamping range
2.8-4.8 mm
4.8-6.8 mm
Blind rivet N3 Blind rivet N3 83 19 0 301 421 dia. 4 mm; clamping range
1-3 mm
Punch rivetN4 Punch rivetN4 83 19 2 457 307 dia. 3 mm; length 4 mm
Punch rivetN5 Punch rivetN5 83 19 2 158 079 dia. 5 mm; length 5 mm
Blind rivet N6 Blind rivet N6 83 19 2 158 655 dia. 4 mm; clamping range
3-5 mm
1.5-3.5 mm
6.8-8.8 mm
8.8-10.8 mm
10.8-12.8 mm
Blind rivet N11 Blind rivet N11 07 14 7 391 057 Blind rivet for carbon
connections
dia. 4.8 mm; clamping range
2.2-4.7 mm
Blind rivet N12 Blind rivet N12 07 14 7 391 046 Blind rivet for carbon
connections
dia. 4.8 mm; clamping range
4.5-7.5 mm
2.1 Plastic nuts
Cap nut Plastic nut 51 16 1 943 122 Dia.
18 mm
Cap nut Plastic nut 07 14 7 169 847 Dia.
22 mm
3.0 Primer/paint spray aerosol
Designation, repair Naming of Electronic Parts Part number of Electronic Remarks

instructions Catalogue Parts Catalogue
Primer Emergency program base filler 51 91 0 432 615 200 ml;
2K spray application time
8h
Welding primer INOX spray welding primer 83 40 0 409 992 500 ml
Paint spray aerosol, Paint spray aerosol, inside filler 51 91 0 411 026 400 ml
cathodic dip coating, grey of spare wheel well
Spray can, black, matte Spray paint, black matt 51 91 1 900 346 400 ml
4.0 Sealant
Sealant D1 Seam sealing 83 42 2 409 985 310 ml
Sprayable sealant
Sealant D2 Seam sealing, spreadable 83 42 2 409 986 310 ml
5.0 Cavity preservation
Cavity sealant Cavity sealant spray 83 42 2 457 337 400 ml
Cavity sealant Cavity preservation 83 42 2 457 338 1000 ml
6.0 Cavity foam
Cavity foamHS1 Cavity foam 83 42 9 410 694 400 ml
Structural foamHS2 Structural foam 83 19 0 007 361 420 ml
Cavity foamHS3 2K polyurethane foam 83 42 2 288 930 50 ml
7.0 EMC screw (electromagnetic compatibility)
EMC screw Screw 83 19 0 301 639 SF Plus
M5x15
8.0 Twist drill
Drill bit Drill bit 83 19 2 460 424 4.2
x 120 mm
Drill bit Drill bit 83 19 2 460 425 6.8
x 150 mm
Drill bit Twist drill 83 19 2 166 463 4.2
x 55 mm
Drill bit Twist drill 83 19 2 166 464 6.8
x 74 mm
Drill bit High-strength drill 83 19 2 359 262 6.8
x 79 mm
Drill bit High-strength drill 83 19 2 359 263 4.2
x 66 mm
9.0 Grinding material
Non-woven abrasivesS1 ScotchBrite Multiflex A, very 51 91 0 402 967
fine
10.0 Spacer
Spacer Adhesive tape 51 71 7 901 759
11.0 Adhesive tape
Aluminium adhesive tape Adhesive tape 11 00 7 769 948 Width
50 mm
12.0 reinforcement plates

Reinforcement plate, Reinforcement plate, universal 41 21 7 275 563
universal
41 00 ... Punch rivets
The "Bonding and Riveting” repair method involves the use for the first time of punch rivets in the repair. This
requires new tools and procedures.
The punch rivets are matched in size to the material thickness and quality used at the respective connection
point.
Punch rivet tool (see Service Information 05 03 09 (535))
Sourcing reference via Aftersales Assistance Portal (ASAP) - Service/Technology - Workshop Equipment
(Start BMW) - Shop Workshop Equipment or at www.bmwgroup-wep.com.
Setting punch rivets:
Refer to the vehicle-specific repair instructions for the punch rivet size.
Mark the positions of the rivets on the vehicle. Set punch rivets at roughly equal spacings.
Punch rivets do not require a predrilled hole. They are pressed directly into the full material.
Insert punch rivet in riveting die. Position punch rivet tool on sheet metal parts to be riveted.
Riveting direction:
Always from new part to used part.
Deviations are specified in the vehicle-specific repair instructions.
Rivet punch rivets with punch rivet tool. In the meantime clean riveting die and matrix if fouled with
adhesive.
Seal punch rivets in moist area (e.g. wheel arch or carrier support) on both sides with sealantD1 (risk of
corrosion).
Seal cavities after painting vehicle with cavity sealant (risk of corrosion).
41 00 ... Quality standard
The overall requirements relating to a vehicle can only be implemented by including "all" components.
This applies in particular to the body. With regard to an optimum crash result, it is necessary to maintain
the structural measures.
The procedures described in the repair instructions must be complied with. Deviations are only permitted
after arrangement with and approval by BMW. Should you have any questions, please contact the
country-specific Hotline.
The use of non-approved repair steps or tools may have serious consequences for the structure of the
vehicle (e.g. in the event of a crash). In the end, this can result in safety and product liability risks which
cannot be calculated.
Corrosion protection measures during and after repair work are vital for ensuring the vehicle retains its
value.
For repair work, only use original BMW/MINI parts, or parts that are of an equivalent quality, and approved
auxiliary materials and operating fluid.
For repairs that are settled by a warranty or goodwill, only original BMW/MINI parts may be used.
41 00 ... Recommended working methods and tools
1. Cutting Out Damaged Parts:
Before starting work, define the connection point in accordance with spare part.
Roughly cut out damaged part inside the connection point.
Caution!
Be careful not to cut through and damage sheet metal underneath.
Remove sealing compound, anti-drumming compound and, if applicable, paint to neutralize the joints. Drill
off welding spots. When drilling out, ensure that drill holes only appear on part which is being cut out. Do
not drill in the remaining connection flanges.
Grind off welded seams carefully with a disc grinder. Heat brazed connections with an autogen torch! Don't
overheat! Take off scrap metal. Remove remaining springy brazing solder with a steel brush. Straighten
and grind off all joint surfaces thoroughly.
2. Installing New Parts:

Prepare joints according with pertinent repairing instructions.
Repairs regarding suspension points for engine or transmission and running gear parts, must be carried
out on a straightening bench using the set of attachments for a certain vehicle type. Other attachments
are also available for various body parts. Check deflection and dimension of front and rear windows by
installing an original window. Refer to relevant drawings for gaps of doors, engine bonnet and luggage-
compartment lid.
Coat joints required for resistance spot welding with zinc dust paint. Only remove protective paint from
galvanized replacement parts. Drill 8 mm dia. holes in joints not accessible for spot welding tongs, using
the spacing of drilled off welded spots, and plug spot weld these joints.
Produce inert-gas welded seams according to the cut-out part.
Produce brazed joints with heat dispersion limited to a minimum and without overheating. Joining methods
which deviate from standard production will be described in the repairing instructions. Grind down welded
seams on visible outside surfaces.
Caution!
Do not grind down thickness of sheet metal.
Grind down and fill in irregularities with tin. After tinning the surface should be prepared to such an extent
that only a coat of fine filler has to be applied in the paintshop.
All welded seams sealed off with body sealing compound in original state must be sealed off again
thoroughly immediately after repairing. Damaged anti-drumming compound must be replaced.
New sheet-metal parts or cavities, seams, cracks and folds formed by new sheet metal parts must be
sealed immediately with a body-sealing compound.
41 05 800 Releasing bonded folded seam connections
Remove area (1) of bead edge on wheel arch bend with a one-hand angle grinder and rough grinding
wheel.
Heat area (2) with hot air blower.
Caution! Extract vapours and gases.
Release connection flange with chisel.
Grind adhesive residue (4) off wheel arch connection flange.
Caution! Wear a grinding dust mask.
Remove remnants of sealing material in area (3).
41 00 ... Removal of PVC material in repair area
Body protection after repair work starts by stripping PVC underbody protection, sound deadener and seam
sealant away from the repair area.
Remove PVC material with a rotating steel brush, or heat PVC to maximum 180° C with a hot air blower and
scrape off with a spatula. When burning off PVC material or heating above 180° C with a gas burner or similar
tool, highly-corrosive hydrochloric acid forms and, in addition, hazardous vapours are emitted. The new lining
does not form a satisfactory bond with burnt PVC material which means that subsequent sub-surface rust may
set in.
41 00 ... Repair methods, repair stages 1
All work as part of which screwed body components must be replaced.
Repair techniques -> Repairing threads

Repair stage 1a
-> Blind rivetÂ
-> Blind rivet nuts and bolts
-> Glass pane
All procedures during which repairs are to be done on the outer skin.
Repair techniques -> Straightening outer skin -> Straightening aluminium parts
Repair stage 1b
-> Straightening steel components
-> Repairing plastic components
-> Grinding -> Grinding aluminium components

-> Grinding steel parts
41 00 ... Repair solution for straight shank/hexagon rivet nut
Protective measures!
Wear safety goggles
Wear protective gloves
Important!
To prevent the material from tapering, do not drill out the rivet head.
1. Carefully spot-drill rivet head with a larger drill bit/countersink
Important!
Avoid paint damage
2. Knock rivet head away with a chisel
3. Punch through rivet shank into cavity, remove if necessary

4. Clean component, eliminate paint damage if necessary
If the rivet shank can be removed: Important!

To avoid corrosion, stop chips/swarf by means of cavity
preservation.
Follow notes on corrosion protection.
5. Preserving cavity
If the rivet shank cannot be removed: Warning!

Danger of injury!
Observe notes on cavity foam.
Important!
To avoid corrosion and rattling noises, stop chips/swarf and rivet nut
shank with cavity foam.
Remove foam remnants with isohexane (benzine).
5. Stop rivet shank by means of specific foaming

6. Set rivet nut with hand rivet gun
Note:
Fit rivet nut as quickly as possibly, ideally before the cavity foam
hardens.
gun ZS308 Important!
Make sure rivet nut correctly contacts component.
Note:
gun MB512 Important!
Make sure rivet nut correctly contacts component.
Note:
41 00 ... Repair techniques, repair stage 2
Repairs that are carried out by bonding and riveting and/or welded with MAG welder without the use of a
straightening bench.
Repair techniques -> Removing used part -> Opening welded connections
-> Opening brazed connections
-> Opening rivet connections
-> Opening bonded connections
-> Grinding aluminium components

-> Grinding steel components
-> Sectional repair -> Reinforcement plate (bonded)

-> Installing new part -> Notes on consumables
-> Notes on adhesive
-> Bonding on painted surfaces
-> Blind rivet
-> Punch rivets
-> Welding steel components
-> Cavity sealing
-> EMC screws
Repairs that are carried out by bonding and riveting with the use of a straightening bench or welding.
Repair techniques -> Straightening structure -> Straightening aluminium components on the structure
-> Straightening steel components on the structure
-> Removing used part -> Opening welded connections

-> Opening brazed connections
-> Opening rivet connections
-> Opening bonded connections
-> Removing carbon components
-> Grinding aluminium components

-> Grinding steel components
-> Sectional repair -> Welding in reinforcement plate (sheet steel)

-> Sectional repair (steel) with repair element
Sectional repair (aluminium) with repair element
-> Installing new part -> Welding aluminium components
-> Welding steel components
-> Spot-weld bonding steel components
-> Soldering steel components
-> Notes on consumables
-> Notes on adhesive
-> Bonding aluminium on steel
-> Bonding steel on steel
-> Blind rivets
-> Punch rivets
-> Cavity sealing
-> EMC screws
63 12 ... Repairing headlights
It is possible to repair the following damage:
Deformed or broken holders can be replaced using the available repair kits.
Replacement of headlight is not required!
For reasons of pedestrian safety it is not permitted to use adhesive or reinforcements to repair broken
holders!
Note:
Headlight repair kits are not available for every vehicles (see Electronic Parts Catalogue).
It is not possible to repair the following damage:

Deformed or broken headlight housing.
Scratched or damaged headlight lenses
The standard coating of headlight lens cannot be restored. Commercially available repair systems are
unable to provide sufficient protection from ultraviolet radiation and external influences (stone chipping).
41 00 ... Repairing plastic components
1.0 General notes
In general, the economic viability must be checked prior to the repair.
The following painted components on the outer skin are suitable for repair:
Bumper panels (exception: E52)
Side sill trim panels
Side Panels
Door outer skin
Hardtop/roof
Soft top compartment lid
Rear lid
Slight deformations without visible cracks in the paint.
Visible cracks reach the component and it is not possible to permanently rectify the damage.Cracks
once again become visible on the paintwork after a certain period of time.
Slight damage, e.g. scrapes, if the component underneath does not become visible.
Cracks, holes up to 2.5 centimetre in length.
Cracks must not reach the edge of the component.
Attention!
The following components cannot be repaired:
Components that are not painted as standard.
Unable to restore grained surface.
Fuel tank, fluid tank (e.g. window washer system, brake fluid, coolant expansion tank, etc.)
2.0 Reshaping of plastic parts
A hot air blower can be used to reshape plastic parts as per the aforementioned criteria.
3.0 Bonding of plastic parts
Important!
A plastic repair box is offered (sourcing reference via BMW Parts Department) for inexpensive repair with
fair time values.
The procedure for repair of plastic parts is included in the plastic repair box.
Clamps or other metal reinforcements must not be used for reasons of pedestrian protection.
4.0 Welding plastic parts
Plastic welding procedures are permitted as they are cost-effective repairs in line with the components'
current value.
Clamps or other metal reinforcements must not be used for reasons of pedestrian protection.
41 00 ... Replacing blind rivets

2 348 128
72 1 210
Important!
Lay out protective mats to protect the interior equipment against
swarf from the drilled-out rivets and damage.
Lay out protective mats in the relevant working area:
Instrument panel
Entrance area
Passenger compartment
Schematic diagram of folding pack holder for head airbag:

Drill off rivet plate down to rivet shank with a 10 mm twist drill bit.
Described for grab handle holder:

Drill out all blind rivet protusions (1) up to the body.
Installation note:
Apply primer to paintwork damages on side frame.
Note:
Depending on accessibility, the rivet heads will have to be removed
using special tool 2 348 128 or 72 1 210 .
In areas that cannot be reached using special tools, cavity foam
HS3must first be applied around the rivet head before the rivet head is
then punched out immediately..
Removal of rivet head with special tool 2 348 128:

Press off rivet heads (1) using special tool 2 348 128 and remove.

Shank (1) of special tool 72 1 210 is flexible and can be adapted to the
relevant body contours.
Note:
Insert butyl in the collecting tray (2) to secure rivet heads and prevent
them from falling out.
Insert special tool 72 1 210 through bore hole in body next to attachment
points.
Position special tool from rear on rivet head in cavity.
Note:
A second person will be needed to help hold the special tool on the rivet
head during the driving-out operation.
Make sure collecting tray is correctly fitted on rivet head.
Drive out stem with hammer and 6 mm punch.

Carefully feed special tool out of body so that rivet head does not fall out
of collecting tray.
Note:
If the rivet falls out of the collecting tray into the side frame when the
special tool is fed out, this area must be generously filled with foam.
For details of procedure for filling cavities with foam, see further
operations.
Use cavity preservation (refer to BMW Group Parts) for foam filling.
Cavity foam (refer to BMW Group Parts) may also be used if required.
Fit tube to foam can.

Push the hose in through the pillar holes.
Fill cavity with a filling material.
Warning!
Empty foam can completely onto cardboard and after hardening
dispose of foam and can in residual waste.
Can may burst if not completely emptied.
Overview of rivet gun:

Riveting of gas generator housing and holders for folding pack with rivet
gun (refer to BMW Workshop Catalogue).
The interchangeable head is changed for the different work operations.
Riveting of gas generator housing with:
1.) 17/36 nosepiece and short shank
Riveting of holders for folding pack:
2.) 17/40 nosepiece and long shank
41 00 ... Riveting steel components
Manual riveting tool for blind rivet nuts and bolts.
2.0 Setting blind rivet nuts and blind rivet bolts:
Drill bore holes (0.2 mm larger than the outer diameter of the blind rivet nuts or blind rivet bolts).
Blind rivet nuts and bolts must have a special coating for corrosion reasons.
See Aftersales Assistance Portal (ASAP) - Service/Technical - Workshop equipment (StartÂ BMW) -
Shop Workshop equipment or at www.bmwgroup-wep.com
Use the blind rivet nuts and bolts supplied in the case of the manual riveting tool for steel only!
Insert blind rivet nuts or bolts and tighten down with the riveting tool.
41 00 ... Safety at work
Note national regulations.
1.0 Compressed air:
Air guns must not be pointed at individuals. "Blowing off" the body with compressed air may lead to
serious injury.
The devices are not permitted to be cleaned with compressed air due to dust contamination.
2.0 Electrical systems/devices:
Only perfectly functioning systems and devices may be used.
Repairs on electrical systems and devices must only be performed by certified electricians.
3.1 Working with aluminium dust:
Wear a fine dust mask.
The following applies only to E52 and BMWi: Use explosion-proof exhaust extraction unit.
3.2 Removing sealant.
Hydrochloric acid is created when PVC sealing material is heated to temperatures in excess of 180 °C.
Remove PVC sealant with a rotating wire brush only or heat material with a hot air blower to maximum 180
°C and remove with a spatula.
For good ventilation or direct extraction.
3.3 Arc welding and brazing solder:
Important!
The extremely bright arc during welding may cause serious injury to the eyes if appropriate protective
measures are not taken.
Use a welding screen suitable for the relevant welding method (metal active gas or metal inert gas).
Separation of workbays with protective curtains.
Use a welding-emissions extractor facility.
Wear protective clothing and gloves suitable for welding (not combustible).
A fire extinguisher must be located within reach of the welding area.
Do not carry out any welding work in the proximity of a fuel tank e.g. when it is installed.
3.4 Working with chemical products (adhesive, cleaning agents, fillers, etc.):
Heed the manufacturer's material safety data sheets.
Important!
Handling chemical products may result in allergic skin and breathing reactions.

Avoid direct contact with eyes and skin.
Wear safety goggles, protective gloves and if necessary an apron.
For good ventilation or direct extraction.
Use a breathing apparatus with a suitable filter type when ventilation is insufficient.
Wear impermeable protective clothing.
Immediately change contaminated work clothing.
After finishing work, thoroughly clean your hands and apply protective skin cream.
Always keep an eye douche on hand, change the water regularly (once a month).
Store bonding products in a secure cabinet only.
Keep bonding products away from naked flames and other ignition sources.
Protect bonding products against strong heat sources and direct sunlight.
First Aid:
If product comes in contact with eyes, immediately flush with running water for about 10 -15 minutes.
Seek the advice of eye specialist.
In the event of skin contact and where applicable an allergic skin reaction, clean the affected areas
immediately with soap and water and then apply silicone-free skin cream. If necessary, consult a
doctor.
If an adhesive product is swallowed, rinse mouth/parts of mouth thoroughly with running water. Drink 1-
2 glasses of water. Do not induce vomiting. Consult a doctor.
After inhaling adhesive vapours ensure ample supply of fresh air. Stay calm. Keep air passages open.
Consult a doctor.
3.5 Working with carbon dust:

After finishing work, thoroughly clean your hands. Use protective hand cream.
Fire, smoking and naked flames are forbidden.
Wear work clothes, safety shoes, safety goggles and protective gloves.
Only carry out grinding and cutting work with explosion-proof extraction (BMWi only).
Wear ear protectors.
Wear a dust mask (minimum protection class FFP2).
Avoid carbon dust contact with skin, eyes and clothing.
Regularly clean the working area with a vacuum cleaner and wipe the surfaces with a damp cloth.
Separate workbay by means of mobile partition walls or protective curtains.
41 00 ... Safety instructions for handling magnets
Precautionary measures are necessary when handling magnets in order to exclude any potential danger.
If the distance between the magnets falls below the minimum distance, the magnets will be abruptly attracted
to each other. The brittle magnets will then collide with each other at high speed.
Very sharp splinters (similar to glass splinters) may then be chipped off.
Crush or cut injuries may also be caused.
Observe the manufacturer's safety data sheets.
Warning!
Danger of crush injuries
Danger of injury due to splinters
Danger of injury due to magnetic fields
Handling instructions
Persons with heart pacemakers must not use the magnets.
Do not store any iron parts (tools, small parts) close to the magnets.
Keep magnets away from magnetic data media (credit cards, memory cards).
Do not machine the magnets.
Keep the magnets away direct heat and naked flames.
41 00 ... Setting blind rivet nuts and bolts
Studs welded as standard are always replaced by blind rivet bolts.
Drill holes (0.2 mm larger than the outside diameter of the blind rivet nuts or blind rivet bolts).
Blind rivet nuts and studs must have a special coating for anti-corrosion purposes (sourcing reference:
BMW Parts Department).
Use the blind rivet nuts and bolts supplied in the case of the manual riveting tool for steel only!
It will no longer be possible to set a blind rivet nut if the drilled hole is too big. In this event, set a clip nut
(sourcing reference: BMW Parts Department). This nut tightens itself automatically when screwed to the
component.
Insert blind rivet nuts or bolts and tighten down with rivet tool .
Seal blind rivet nuts and blind rivet bolts with sealantD1 (risk of corrosion).
41 00 ... Spot-weld bonding steel components
Important!
Comply with the following topics from ”Body, General”:
Safety regulations .
Handling electrical system, electronics, airbags and restraint systems.
Welding steel components.
Beginning with E65 the spot-weld bonding process is used to increase vehicle rigidity. In partial body
areas, a 1-component adhesive is applied to the spot flanges and this is followed by resistance pressure
spot welding. The adhesive is hardened only after the paint drying process (at approx. 180 °C).
In the case of repairs, adhesive is not applied to the spot flanges. The number of welding spots is
doubled as a substitute for the omitted adhesive.
Minimum distance between welding spots (1) is 25 mm. Important! The minimum distance must not be
undershot! If there is not enough space for twice the number of resistance weld points, each non-made
resistance weld point must be replaced by a MAG weld seam (2). Length of a MAG weld seam = 20 mm.
Set the MAG weld seams at equal intervals distributed on the face.
The following procedures are used as a substitute for spot-weld bonding:

MAG welding (Metal Active Gas welding)
Resistance pressure spot welding (referred to in the following and in the repair instructions as spot
welding).
Adhesive is not applied between the spot flanges on new parts in the case of 2- or multi-sheet joints.
Areas which cannot be reached by the spot-welding tongs can be joined by MAG plug welding. The
number of welding spots is doubled as a substitute for the omitted adhesive.
Exceptions (e.g.E65) are described in the relevant repair instructions. Apply welding spots to existing
welding spots on new part. This is necessary because the adhesive between the spot flanges of the new
part acts as an insulator.
Caution: Extract smoke and fumes during welding work.
41 00 ... Spray gun for cavity sealant
1.0 Delivery specification:

Owner's Handbook
Pressure reservoir spray gun (1) for cavity sealant
Spray set, consisting of spray hoses: Angle nozzle (2) and round spray nozzle (3)
Important!
Prior to start-up read and familiarise yourself with the manufacturer's operating and safety instructions.
2.0 Start-up:
Open the pressure reservoir and insert the cavity sealant in the form of a 1-litre can.
Close the pressure reservoir.
Connect the spray hose to the quick-release coupling.
Connect the device to the compressed air supply.
Operating pressure 2-6 bar, max. 8 bar!
3.0 Operating principle:

Note:
Unlike previous devices you can alter the spray pattern on this device with the air volume regulating screw (large knurled
screw).
Twisting the air volume regulating screw in decreases the air volume and thus reduces the formation of material mist.
This facilitates optimum working when preserving open components/surfaces.
Twisting the air volume regulating screw out increases the air volume and thus increases the formation of material mist.
(For closed cavities)
The trigger has two settings.
1st setting - air discharge only.
2nd setting - air and material discharge.
After finishing work, press the first setting to clean the spray hose with compressed air.
Prior to storing, remember to twist the air volume regulating screw closed to reduce the risk of the material drying out.
Prior to an extended period of non-use (2 weeks and more), clean the gun.
To ensure that the spray hoses function properly, do not store them coiled up e.g. in the side member area!
Store the spray hoses stretched out.
4.0 Application examples:

Use the appropriate spray hoses for the different types of cavity and surface.
Example - doors, lids and hatches:
Spray hose with angle nozzle. Reduce air volume to keep the formation of mist low.
Example - side members:
Long spray hose with round spray nozzle. The air volume must be increased a little, depending on the type used.
Basically, keep the formation of mist low to avoid fouling and unpleasant odours.
5.0 Safety instructions:

Do not inhale spray mist.
Use in well ventilated rooms only.
Operating pressure max. 8 bar.
41 00 ... Stamping vehicle identification number
If the stamped VIN (Vehicle Identification Number) is removed during

repair work, this number must be stamped again.
To stamp vehicle identification number, remove spring strut at front
right.
The special tool kit 41 1 030 for stamping the VIN comprises:
Guide plate 41 1 031 (1)
Counter plate 41 1 032 (2).
Fit special tool 41 1 032 (2) at bottom under spring strut support plate.
Fit special tool 41 1 031 (1) at top on spring strut support plate and
secure.
Insert stamp numbers 41 1 002 (1) individually in special tool 41 1 031 (2)
then stamp VIN.
In the event of component or body replacement by the garages, clearly
delimit the vehicle identification number at front and rear by stamping a ”+”
in place of the BMW emblem.
41 00 ... Straightening aluminium components
1.0 Recommended tools
Use only those tools specially intended for aluminium repairs (refer to Service Information 5 03 03 975).
Do not use any tools that have already been used for steel repairs (contact corrosion).
Do not use any sharp-edged tools (notch effect).
2.0 Straightening outer skin
”Cold” straightening: Press dents out from their centre and smooth in an outwards direction with gentle
taps.
In the case of small, soft dents (hail and parking damage), this is also possible without damaging the
paintwork. This work requires a special tool (refer to Service Information 5 04 98 328) and a trained
employee.
”Hot” straightening: Heat dents in their central point only with a gas flame or hot air blower. Then quench
the material with a wet cloth. Heating can only be detected by a curvature of the material. The colour of
the material does not change.
In the case of damaged areas which are only accessible from one side, stud welding can be used (refer
to Service Information 5 01 00 532). The aluminium bolt welded on in the centre of the damaged area is
beaten out with a hammer until the dent is eliminated. The bolt is then ground off.
Avoid notching and cracking.
Avoid hardening and overstretching.
Avoid heating and excess temperature the outer skin over large areas.
3.0 Straightening structure
Reshaping or heating extruded profiles and cast parts is not permitted!
Failure to comply with this requirement would have the following results:
During reshaping, weld seams tear (E52) or bonded connections in the surrounding area.
In the case of reshaping, the material loses up to 40 % of its original strength.
In the case of heating, the material loses up to 40 % of its original strength.
The adhesive is destroyed at temperatures ≥120 °C.
Extruded profiles and cast parts which show visible or measurable signs of deformation must be replaced.
Perform the check for deformation with the aid of the straightening system.
For optical testing, strip adjoining components in cases of doubt.
Extruded profiles are used in the E52 as engine supports, door posts, side members, etc.
Extruded profiles are used in the E60, E61, E63, E64 as engine supports.
F12During E60, E61, E63, E64, E70, E71, E72, F01, F02, F04, F07, F10, F11, F12 cast parts are inserted as
spring strut dome.
Exceptions on the E60, E61, E63, E64:
Carrier support and bulkhead may be straightened if they do not have any cracks, sharp-edged damage
or holes. After repair work, check parts again for cracks.
Examine adjoining adhesive flanges for peeling off. If necessary, seal and preserve with sealant.
Observe the frame reference dimension for the carrier support.
Any repairs to the bulkhead if cracked outside the approved scope of repair work are only permitted after
consultation with and approval by BMW. Should you have any questions, please contact the country-
specific Hotline.
Reshaping of extruded profiles and cast parts may only be used to achieve optimum joining of connection
faces (e.g. when bulkhead is damaged). Reshaped parts must be replaced.
Repairs which affect the attachment points of mechanical assemblies and chassis/suspension
components must be carried out on the straightening bench. Use the vehicle-specific set of attachments
set or vehicle-specific data sheet.
Straightening attachment supports and data sheets are also available for the top section, e.g.: door
posts, soft top mounts, cowl panel, tailgate hinges, etc.
Check windscreen and rear window apertures for curvature by inserting the original glass.
Take the gap dimensions for doors, engine compartment lid and tailgate from the vehicle-specific gap
dimension diagram.
41 00 ... Straightening steel components
1.0 Recommended tools
Only use those tools designed for steel repairs.
2.0 Straightening outer skin
”Cold” straightening: Press dents out from their centre and smooth in an inwards direction with gentle taps.
In the case of small, soft dents (hail and parking damage), this is also possible without damaging the
paintwork. This work requires a special tool (refer to Service Information 5 04 98 328) and a trained
employee.
”Hot” straightening: Heat dents in their central point only with a gas flame until bright red hot. Then quench
the material with a wet cloth.
Stud welding can be used in the case of damage with accessibility only from one side (see Aftersales
Assistance Portal (ASAP) - Service/Technical - Workshop equipment (Start BMW) - Shop Workshop
equipment or at www.bmwgroup-wep.com). Weld on stud in the middle of the damage. The steel pin or
washer is knocked out using a panel puller until the dent has been removed. The stud. pin or washer is
then sanded or turned off.
Avoid cracking.
Avoid hardening and overstretching.
Avoid heating and excess temperature the outer skin over large areas.
When the surface exhibits an unevenness no greater than 2 mm after straightening steel parts, filler may
be used to even out the area.
If the unevenness is greater than 2 mm, it is necessary to carry out rounding off/tinning.
Note:
Only applicable within the European Union!
European used-vehicle regulations prohibit the use of tin containing lead in motor vehicles introduced
after 01.07.2003!
For high-security vehicle, note the special information in the repair instructions!
3.0 Straightening structure
Repairs affecting the attachment points of assembly and chassis/suspension components must be
carried out on the straightening bench with the matching set of attachments set or data sheet for the
vehicle.
Alignment brackets and data sheets are also available for the top section, e.g.: door posts, soft top
mounts, cowl panel, tailgate hinges, etc.
Check windscreen and rear window apertures for curvature by inserting the original glass.
Take the gap dimensions for doors, engine compartment lid and tailgate from the vehicle-specific gap
dimension diagram.
Bearing body components such as e.g. engine supports, door posts, side members etc. with
deformations which can no longer be returned to their original shape by ”cold straightening” must be
replaced.
Heating bearing body components for better reshaping is not permitted!
Failure to comply with this requirement would result in a loss of original strength of up to 40 %.
High-strength and super-high-strength steel plates as a rule cannot be reshaped. Reshaping only serves
as a preparatory measure to replacing the component in order to achieve optimal joining of the
connection faces.
The body must be anchored as follows for reshaping:
If using vehicle-specific/universal set of attachments sets (Carbench/ Celette), it is necessary to secure
the body additionally with 4 retaining clamps at the spot flange of the entrance or at the 4 jacking points.
The spot flange (if available) is to be preferred.
If using universal electronic or mechanical straightening systems (Car-O-liner/Celette), it is necessary to
secure the body with 4 retaining clamps at the spot flange of the entrance or at the 4 jacking points. The
spot flange (if available) is to be preferred. In addition anchor at least 2 points with the securing set.
Failure to comply with these instructions will result in damage to the body during reshaping in non-
damaged areas. Vehicle-specific alignment brackets and universal mounts may be damaged.
99 00 ... Touching up paintwork damage
These notes apply to paintwork damage on the body aperture that occurred when detaching bonded window
glass.
To ensure long-term corrosion protection, it is absolutely essential to touch up damage to paintwork!
The ”BMW Color System” painting handbook forms the basis of these repair instructions and must be
observed without fail.
Ground down damage to paintwork on body aperture and touch up with BMW multibase filler.
Grind larger areas or damage down to the bare sheet metal and coat with BMW multibase filler (layer thickness
30 to 40 μm).
Hardening time:
With infrared, at least 10 minutes
Without infrared for at least 60 °C, at least 30 minutes
Without infrared for at least 20 °C, at least 24 hours
If a complete build-up of paint is required in the visible area:
Tape off primed adhesive flange before applying top coat
Important!
Observe hardening time of BMW multibase filler otherwise a perfect bond cannot be guaranteed!
41 00 ... Use of materials in outer skin
The following illustration is a schematic diagram of all the body variants.

Apply this illustration to the relevant vehicle.
All components not listed in the table below are composed of established sheet steel qualities.
Component Vehicle Material

(1) Side wall, front E52 (Z8) Aluminium
E60, E61 Aluminium
E63, E64 Plastic (thermoplastic)
E65, E66 Aluminium
E70, E71,E90 (M3), E92, E93 Plastic (thermoplastic)
E89 (Z4) Aluminium
(2) Front door E36/C (M3) Aluminium or steel
E36/2 (M3) Aluminium or steel
E52 (Z8) Aluminium
E63, E64 Aluminium
(4) Side wall, rear E52 (Z8) Aluminium
(5) Engine compartment lid E38 (750i) Aluminium or steel
(5) Engine compartment lid E46/C (M3) Aluminium
E46/2 (M3) Aluminium
E52 (Z8) Aluminium
E60, E61, E63, E64 Aluminium
E65, E66, E70, E71 Aluminium
E85 (Z4) Aluminium
E90 (M3), E92 (M3) Aluminium
E89 (Z4) Aluminium
(6) Hardtop/ roof E36/C Aluminium
E36/7 (Z3) Plastic (glass fibre / epoxy resin)
E46/C Aluminium
E46/2 (M3 CSL) Plastic (CFK)
E52 (Z8) Plastic (PU)
E85 (Z4) Plastic (SMC)
E63 (M6) Plastic (CFK)
E89 (Z4) Aluminium
(7) Soft top compartment lid E46/C Magnesium
E64 Plastic (SMC)
(8) Tailgate E46/2 (M3 CSL) Plastic (SMC)
E52 (Z8) Aluminium
E63, E64 Plastic (SMC)
41 00 ... Welding and soldering steel components
Important!
Comply with the following topics from ”Body, General”:
Safety regulations.
Handling electrical system, electronics, airbags and restraint systems.
A. Welding steel components:

1. General information
The following procedures are used for repairs:
MAG welding (Metal Active Gas welding)
Resistance pressure spot welding (referred to in the following and in the repair instructions as spot
welding).
Take the number and position of welding spots and MAG weld seams from the separated part. Replace
areas inaccessible to spot-welding tongs with MAG plug weldings at the same distance. Diameter of bore
holes for plug weldings 8 mm.
In the case of emissions extraction, observe a minimum distance of 30 cm for MAG welding during the
welding process. Otherwise the inert gas would be drawn off.
Follow the equipment manufacturer's instructions for use.
2. Work materials
MAG welding:
Steel welder (see Workshop Equipment).
Steel welding wire ‐ G3SI1 (SG2) or alternatively G4SI1 (SG3)
Welding mask
Gas bottle containing inert gas (82 % argon, 18 % CO2)
Resistance pressure spot welding:

Spot-welding apparatus (see Workshop Equipment).
Safety goggles
3. Preparations for MAG and spot-welding
Remove the paint coating in an area of approx. 30 mm around the weld seam or spot.
The zinc layer underneath must be removed during the MAG welding method.
It is not necessary to remove the zinc layer underneath during spot-welding.
Remove the paint coating on the reverse side of the weld seam or spot.
Contaminants will otherwise enter the weld pool via the root of the weld seam.
An insufficient electron flow prevents an optimum spot-weld joint.
Coat all metal overlaps and weld spot flanges with welding primer.
To determine the optimum electrode contact force for spot-welding, carry out spot-weld shear tests on
sample sheet metal.
In order to keep the electron flow short during MAG welding on the body, you must if possible attach the
ground terminal directly to the component to be welded.
4. Welding
During MAG welding, the weld gap must be kept as small as possible. The larger the weld gap, the lower
will be the strength of the joint.
During spot-welding, the sheet metal flanges to be joined must be placed as close together as possible
without gaps.
The larger the gap, the lower will be the strength of the joint.
Minimum distance between welding spots 25 mm.
5. Subsequent treatment of welded connections:
When grinding a weld seam, do not grind thin the base material next to the seam.
After joining, clean all weld seams and spots with a stainless steel wire brush.
Remove burnt paint with a stainless steel wire brush.
All welded connections sealed off with body sealing compound in original condition must be primed and
sealed off again thoroughly after repairing. Replace damaged or removed anti-drumming layers.
B. Soldering steel components:
The following procedures are used for repairs:
Autogenous brazing solder
Tinning
The MIG soldering procedure is not used in repairs for strength reasons. MIG soldered/brazed seams
used in standard production are replaced during repairs by MAG weld seams.
Areas brazed in vehicle production are joined during repairs with the same procedure.
It is possible when straightening steel components to correct irregularities smaller than 2 mm with filler.
If in exceptional cases the irregularities are in excess of 2 mm, these areas must be tinned.
Only visible areas of the outer skin and on the carrier support must be tinned.
All areas which have covers on the vehicle are not to be tinned.
Note:
European used-vehicle regulations prohibit the use of tin containing lead in motor vehicles introduced
after 01.07.2003!
2. Work materials
Brazing solder:
Tube pack and torch (autogenous torch)
Brazing solder
Gas bottles (oxygen and acetylene)
Welding goggles
Tinning:
Tube pack and torch (torch for tinning)
Tinning paste
Tin (refer to ”Electronic Parts Catalogue”).
Gas bottle (acetylene)
Safety goggles
3. Preparations for brazing solder and tinning
Heat brazed connections to be opened with gas flame. Lift off sheet metal remnants and remove
remaining brazing solder with wire brush.
Remove the paint and zinc layer in an area of approx. 30 mm around the seam to be soldered.
Remove the paint and zinc layer in the tin-plating area and approx. 30 mm beyond.
4. Brazing solder/tinning
Execute brazed seam without overheating the solder and with low heat dissipation. If necessary, use
heat protecting paste.
5. Subsequent treatment of brazed connections:
Remove burnt residual zinc completely. Straighten, grind and tin visible connection faces.
Remove burnt paint with a stainless steel wire brush.
41 00 ... Welding in reinforcement plate (sheet steel)
In the case of a partial replacement piece, a body component is cut at a

point described in the repair instructions.
A reinforcement plate is welded in to ensure sufficient strength.
Follow notes for welding steel components.
Note:
The following graphics serve as general illustrations of reinforcement
plate repair work. They are applicable to all sectional repairs.
Mark component in accordance with dimension A and cut.
Cut new part (1) in accordance with cut and if necessary adjust to fit with
alignment bracket or universal mount.Installation note:
Maintain a distance of approximately one to no more than two material
thicknesses at the severance cut to ensure welding with the
reinforcement metal and enable more tolerant adjustment.
Clean inner and outer sides of connection faces (1) on new part and (2)
on body.
Coat insides with welding primer.
Drill bore holes (1) and (2) at distance of 25 mm to each other.
Hole diameter approx. 8 mm.
Make reinforcement plate (1) from trim of new part.

If applicable, produce more reinforcement plates.
Length of reinforcement plates is min. 40 mm.
Coat reinforcement plates (1) and (2) on both sides with welding primer.
Push reinforcement plate (1) into component on body up to half way and
plug-weld (2).
If applicable, adjust the new part (1) with the alignment bracket or
universal tool and plug-weld (2)
MAG weld the joint (3).
Grind and clean weld seam and plug weld spots.
Only visible areas of the outer skin and on the carrier support must be
tinned.
All areas which have covers on the vehicle are not to be tinned.
Note:
European used-vehicle regulations prohibit the use of tin containing lead
in motor vehicles introduced after 01.07.2003!
41 00 ... Welding of galvanized plates
Hot galvanized and galvanized sheet metal is used to a greater extent for components of the body, which are
especially subject to corrosion.
Conformance with the following points is necessary when working with these parts.
The welding smoke contains poisonous zinc oxide, so that especially good extraction is necessary in the
welding bay.
Do not grind off zinc coat for resistance spot welding and inert gas welding. The zinc coat must be ground
off for brazing jobs.
If at all possible, welded connections should be made with resistance spot welding. Increase welding
current by at leastÂ 10% over value for non-galvanized plates. Apply highest possible electrode contact
force (make break out test on sample sheet metal). A coat of spot welding paste can be applied for better
sealing.
Inert gas welding should be preferred to autogen welding in areas not accessible for resistance spot
welding, because of the lower heat dispersion.
Machining or forming of galvanized sheet metal in warm state is normal. Make sure that extraction of
poisonous vapours is carried out thoroughly.
Remove burnt residual zinc completely. Align, grind down and tin out visible joints as normal.
Coat ground-off zinc coat with zinc dust paint.
41 00 ... Window and door seams E46, 4-door
All dimensions in mm.

A - A: F - F:
a = 4.25 ± 0.75 a = 4.0 ± 0.75
b = 0 + 1.0 b = 0 + 1.0
c = 15.0 ± 2
B - B:
1 = Side frame G - G:
2 = Front door a = 15.0 ± 2
3 = Windshield b = 1 + 1.0
a = 12.8 ± 0.2 c = 4.5 ± 0.75
b = 4.5 ± 1.0 d = 15.0 ± 2
C - C: H - H:
a = 13.9 ± 2 a = 8.8 + 3
b = 4.0
c = 25 ± 1 I - I:
d = 15.0 ± 2 a = 0 + 1.0
b = 4.5 ± 0.75
D - D:
a = 15.7 ± 2 K - K:
b = 4.0 1 = Panel, sill
c = 15.0 ± 2 2 = Sill
3 = Front door
E - E: a = 1.0 ±1
a = 17.2 b = 1.0 ± 1
b = 15.0 ± 2 c = 5 +1.5 -1
41 00 ... Working with 2-component PU cavity foam
Sourcing reference for cavity foam, refer to BMW Parts Service.
Ideal for use as insulating and sealing compound
Wear protective goggles, solvent-resistant protective gloves and protective clothing.
Do not inhale.
Warning!
Application time after mixing: within 8 minutes!
Remaining amounts which are not used can cause the can to explode on account of a chemical reaction
(buildup of heat)!
Alternatively, cool the can containing the non-removed remaining amount for several hours in cold water.
Keep heat and ignition sources well away.
Read the manufacturer's information on hazards/dangers (printed on the can) prior to application.
Application instructions:
Use by date on can.
Do not use the spray can after the Use by date on the can has expired. After the Use by date the
properties of the cavity foam will no longer meet the requirements of the BMW Group.
Cavity sealing of repair area possible after an air drying time of 1 hour.
Backing surface must be
clean and free from
dust,
grease,
Remove fresh, non-hardened PU foam with adhesive cleaner 208.
Sourcing reference: BMW Parts Service.
Hardened PU foam can only be removed by mechanical means (machine).
Excess, hardened PU foam can be disposed of as residual waste.
Cans which are not entirely empty and unused whose Use by date has expired are classed as
hazardous waste.
Observe the manufacturer's application instructions (printed on the can).
Important!
Foam expands many times over as it sets (change in volume).
Setting takes approx. 30 minutes. Mechanical processing (e.g. drilling, cutting, etc.) is then possible.
41 00 ... Workshop equipment (BMW and MINI vehicles)
Minimum requirements for workshop equipment to guarantee professional body repairs:
The tools listed below must be used.
Repair stage 1a:
Tool* Sourcing reference Screwed parts (steel or Screwed parts

plastic) (aluminium)
Body tool trolley 81 64 2 153 204 or x x
81 64 2 410 578
Drill conventional x x
Span width 0 to min.
10 mm
Blind riveting tongs 81 43 0 301 744 x x
Manual riveting machine for blind 81 43 2 155 739 (up to x x
rivet nuts M12) or
81 43 9 429 204 (up to
M8)
Repair stage 1b:
Tool* Sourcing reference Screwed parts (steel Screwed parts

or plastic) (aluminium)
Aluminium bodywork tool 81642336755 x
assortment
Pressure cup spray gun for 81452148795 x x
cavity preservation
Drill conventional x x
Span width 0 to min. 10 mm
Blind riveting tongs 81430301744 with extension x x
81432158706 or
Electrical or pneumatic
81432159003
With rivet head extension
Manual riveting machine for 81432155739 (up to M12) or x x
blind rivet nuts
81439429204 (up to M8)
Repair stage 2:
Steel Aluminium
Tool* Sourcing reference Structure Outer skin Structure Outer skin
Body tool trolley accessory set 81642334947 x x
Bodywork saw 81432156415 or x x
81432410594
Belt sander 81432236488 (230V) or x x x x
81432333873 (100-115V)
Single-handed grinder 81430303336 x x x x
Welding spot remover 81439428600 x x
Punch riveting tool 8132158708 x x x
MAG welding apparatus conventional x x
Cartridge gun for adhesives x x x x
Infrared heater 81442211107 (220V) or x
81452211615 (110V)
Thermometer 81312211265 x
In addition, the repair stage 1 tools are required.

Repair stage 3:
Steel Aluminium
Tool* Structure Outer skin Structure Outer skin
Spot welding apparatus x x
Straightening system x x
Stud welding apparatus x x
Flame coating set x
MIG welding apparatus x (E52 only)
In addition, the repair stage 1 and 2 tools are required.

*Sourcing reference BMW Workshop Equipment Catalogue
Attention!
In vehicles from model year 2001, higher-tensile and high-tensile steels are used in certain areas.
It is essential to check whether the spot-welding apparatus used conforms to the technical
requirements of the currently recommended welding sets. Should you have any questions, please
contact the country-specific Hotline.
The use of technically obsolete equipment may have serious consequences for the structure of the
vehicle (e.g. in the event of an accident). In the end, this can result in safety and product liability risks
which cannot be calculated.
Use and restrictions:

Definition of recommendation:
All currently recommended spot welding sets comply according to the latest information with the requirements
relating to reliable welding of today's and future BMW Group vehicles. A spot welding unit will lose its
recommendation as soon as tests with materials and material combinations designated for future use in BMW
Group vehicles return negative results (see Table Group 1). All previous application before the withdrawal of
the recommendation shall remain unaffected.
Device designation Manufacturer

Group 1 CR500 CAR-O-LINER
Devices currently no longer recommended
Spot9000 Tecna
ATL 400V Wieländer&Schill
MIDIspot QSVM12000T CAR-O-LINER
MIDIspot QSVM12000T Elmatech
MIDIspot QSVM9000 CELETTE
MIDIspot QSVM9000 Elmatech
CR600 QSM CAR-O-LINER
Group 2 Multispot MI-100 Control Elektron
Devices currently recommended
Inverta Spot GT BM Wieländer&Schill
3664 BM Tecna
CTR12000T CAR-O-LINER
Application options and restrictions of above devices.
Vehicle Group 1 Group 2

All BMW convertibles from E64 x x
Except A-pillar, B-pillar, sill
All BMW model ranges from E70 x x
Except B-pillar
Note:
As at May 2016
All BMW and MINI vehicles not mentioned can be repaired with the equipment of Group 1 and Group 2.
.

(1) A-pillar,
refer to 41 00 ...
refer to 41 00 ...
refer to 41 00 ...
refer to 41 00 ...
refer to 41 00 ...
refer to 41 00 ...

refer to 41 00 ...
(8) Entrance, rear,
refer to 41 00 ...
refer to 41 00 ...
B-pillar, inner,
refer to 41 00 ...
refer to 41 00 ...
refer to 41 00 ...

Further scopes,
paint etc.).
Caution!
relative humidity.
Note:
Caution!
Caution!
Parts Service
.
Caution!
Burn hazard!


Caution!
Burn hazard!

41 11 300 Replacing cover for side member, left or right (partial replacement,
B-pillar before A-pillar and side panel, rear) (from 04 / 99)
Work instructions: Refer to 41 00 ... Notes on body repairs.
Note:
Up to 04 / 99, the reinforcement plate in the B-pillar was fitted in a shorter
version.
From 04 / 99, the reinforcement plate has been reinforced in the B-pillar.
The procedure for repair has thus fundamentally changed.
Replace cover for side member, left or right (partial replacement, B-pillar
before A-pillar and side panel, rear) (up to 04 / 99), refer to 41 11 300.
This replacement operation involves the following components:

Side member cover
B-pillar, inside
Remove or disconnect following parts:
Front door
Rear door
Front seat
Front door and rear door edge trim
Front and rear entrance cover plates
Back seat and backrest
A and B column panelling
Safety belt with height adjustment
Front carpet (partially)
Rear carpet (partially)
Left: Lower trim on instrument panel
Right side: Glove compartment
Vehicle parts located in the repair zone or threatened by heat, sparks or
dust, must be removed or covered.
Determine and mark outside B-pillar cutting line:

Reference edge = roof edge
Measurement (C) = 180 mm from roof edge.
Measurement (D) = 260 mm from roof edge.
Alternatively:
Reference edge = upper hinge fixture
Measurement (E) = 350 mm from upper hinge fixture.
Measurement (F) = 430 mm from upper hinge fixture.
Determine and mark inside B-pillar cutting line:

Measurement (A) = 50 mm from centre of hole of upper seatbelt height
adjustment fixture.
Important!
Prior to cutting, support roof!
Important!
Protect ITS head airbag so that it cannot be damaged during welding
or grinding work.
Due to
welding chips
grinding chips
excess heating over 70 °C
the functional capability may be impaired. In extreme cases, it will
not be able to function at all!
Important!
Only separate the outer sheet metal of the B-column.
Cut through marked cutting line of B-pillar, outside, measurements ”C,D”

or ”E,F”.
Drill off spot welding.
Remove metal cutout, ”window”.
Mark cutting line in cut-out area of B-pillar in centre and completely cut
through.
Measurement (A) = 220 mm from roof edge.
Alternatively:
Mark cutting line in cut-out area of B-pillar in centre and completely cut
through.
Measurement (A) = 390 mm from upper hinge fixture.
Cut cutting line, B-pillar, inside.
Determine and mark cutting line for cover for front side member:
Measurement (A) = 150 mm from centre of bore.
1 = 1st bore for finishing strip, entrance
1 = 2nd bore for finishing strip, entrance
Determine and mark cutting line for cover for rear side member:
Measurement (A) = 140 mm from centre of bore for finishing strip,
entrance (1) with dia. 5.5 mm.
Measurement (B) = 140 mm from centre of bore for panel for cover on
side member (2), dia. 9.2 mm.
Cut marked cutting lines on B-pillar and cover for side member.
Drill out welding spots for front and rear door openings.
Remove insulating mats in passenger compartment from cover for side

member.
Expose and open welding spots on underbody.
Expose welding spots on floor plate in area of cover for side member
from passenger compartment side.
Drill out welding spots of B-pillar on cover for side member from
passenger compartment side.
At front seat carrier, drill out welding spots of bulkhead, cover for side
member, from passenger compartment side.
Important!
Do not use a naked flame for heating!
Burn hazard!
Extract vapours and ensure good ventilation.
Position of foam parts,

refer to 41 00 ... Layout of shaped parts for cavity bulkhead
Heat foam in following areas:
B-pillar
Side member cover, rear
Remove side member cover.
Drill out welding spots of remaining metal of extended reinforcement, B-

pillar, on car and remove remaining metal.
Straighten and grind joint surfaces.

Remove foam residue from cavity sealing.
On spare part, cover for side member, determine and mark out cutting
lines for ”window” of B-pillar:
Measurement (E) = 350 mm from upper hinge fixture.
Measurement (F) = 430 mm from upper hinge fixture.
Important!
Only separate the outer sheet metal of the B-column.
Cut through marked cutting line of B-pillar, outside, measurements ”E,F”.

Remove metal cutout, ”window”.
Note:
Cut cutting lines, B-pillar, outside, as on car.
Mark cutting line in cut-out area of B-pillar in centre.

Important!
Only cut through marked sheet metal of B-pillar.
Do not cut through ”extended reinforcement plate” of B-pillar.
Drill off ”extended reinforcement plate”, B-pillar (1), from spare part so that
cut B-pillar can be removed with ”extended reinforcement plate”, B-pillar
(1).
A = measurement of extended reinforcement plate which is 390 mm from
upper hinge fixture above cutting line of B-pillar.
Measurement (A) = 150 mm.
Measurement (A) = 50 mm from centre of bore for finishing strip, entrance
(1) with dia. 5.5 mm.
Measurement (B) = 165 mm from centre of bore for panel for cover on
side member (2), dia. 9.2 mm.
Cut through marked cutting line.
Make reinforcement plates for cover for side member for connection
point
door pillar (A-pillar) and
C-pillar
from remaining metal sheet.
Width of reinforcements: approx. 60 mm.
Drill holes for plug welding reinforcement plates, connection point door
pillar (A-pillar) and C-pillar in body and cover for side member spare part.
Clean connection points at door pillar (A-pillar) and C-pillar on body and
cover for side member spare part and coat with zinc dust paint.
Fit reinforcement plate at door pillar (A-pillar) with 1/2 width in connection
points of body, locate in position and weld up.
Grind down welded surfaces.
Fit reinforcement plate at C-pillar with 1/2 width each in connection points
of body, locate in position and weld up.
Fit cover for side member spare part.

Mark holes for plug welding reinforcement plates.
Remove cover for side member spare part.
Cut expanded foam of cavity sealing on outside of B-pillar flush with metal
edge of B-pillar.
Fill spare part without cavity acoustic baffle with cavity foam.
Install shaped parts for cavity sealing

B-pillar, inside (2),
entrance, centre, inside (cover for side member) (1).
Installation of shaped parts for cavity bulkhead,

refer to 41 00 ... Installation of shaped parts for cavity bulkhead, except
for cover for frame side member
Install cover for side member spare part and locate in position. To install
cover for side member, also fit doors.
Ensure sufficient weld gap of welding point in cut-out area of B-pillar,
”window”.
Weld cover for side member spare part in door aperture.Important!

Do not weld upper welding spots on inside B-pillar (1) as the inside
B-pillar spare part would not then be able to be installed.
Weld reinforcement plate, cover for front side member.
Weld connection point, cover for front side member.
Fit individual welding spots so close together that a continuous seam is
created.
Locate welding spots in a way which prevents distortion caused by heat
elongation. Ensure that welded areas have cooled down sufficiently.
Danger of distortion!
Weld reinforcement plate, cover for rear side member.

Weld connection point, cover for rear side member.
created.
Set welding spots so that no distortion/warpage due to thermal
expansion can occur. Make sure the welding spots have cooled
sufficiently.
Weld cutting line in cut-open area of B-pillar, ”window”.

Ensure sufficient weld gap of welding point in cut-out area of B-pillar,
”window”.
When welding, arrange individual welding spots so close together that an
enclosed seam is created.
Important!
Welded seam may protrude by max. 0.5 mm as otherwise seam
would rest on outer skin, thus causing noises and chafe marks!
If you have to grind off the welded seam, only remove as much
material as is absolutely necessary.
Do not grind in any notches and do not grind off too much material;
otherwise, the rigidity will be impaired.
Weld cover for side member on underbody.
Important!
Combustible foam in welding area!
Avoid overheating.
Extract vapours.
Weld welding spots of B-pillar on cover for side member from passenger
compartment side.
Important!
Avoid overheating.
Extract vapours.
At front seat carrier, weld bulkhead, cover for side member, from
Grind welding spots until they are smooth.
Cut inside B-pillar spare part.

Measurement (A) = 50 mm from centre of hole of upper seatbelt height
adjustment fixture.
Fit inside B-pillar spare part.

Gap between seatbelt height adjustment fixtures (A) = 173 mm.
To fit, install seatbelt height adjustment fixture.
Mark holes for plug welding of
reinforcement plate, inside B-pillar and
inside B-pillar spare part on cover for side member.
Make reinforcement plate from surplus sheet metal.

Reinforcement plate width = approx. 40 mm
Drill holes in B-pillar for plug welding reinforcement plate.
Drill holes for plug welding reinforcement plate in spare part/B-pillar.
Clean connection faces on body and reinforcement plate and coat with
zinc dust paint.
Insert reinforcement plate (1) on inside B-pillar in body and weld up.
Drill holes for plug welding reinforcement plate, inside B-pillar, in spare
part.
Drill holes for plug welding inside B-pillar in cover for side member.
Clean connection faces on body and spare part and coat with zinc dust
paint.
Fit inside B-pillar spare part and locate in position.

Weld reinforcement plate, inside B-pillar.
Weld connection point, inside B-pillar.
created.
Important!
Avoid overheating.
Extract vapours.
Weld holes for plug welding inside B-pillar in cover for side member.
Weld inside B-pillar to B-pillar.

While doing so, weld open spots of inside B-pillar in area of cover for side
member.
Grind down welded surfaces.Note:

Do not grind down welding seam thin in area of contact surface of
seatbelt height adjustment fixture.
Seatbelt height adjustment fixture must rest flat.
Install metal cutout, ”window”, of B-pillar, outside, secure in position and
weld up.
Tin out and grind down contact surfaces.
Coat connection face of cover for front side member with tin and grind
down.
Coat connection face of cover for rear side member with tin and grind
down.
Seal connection points in passenger compartment.

If necessary, reinstall insulating material.
41 11 300 Replacing cover for side member, left or right (partial replacement,
B-pillar before A-pillar and side panel, rear) (up to 04 / 99)
Note:
From 04 / 99, the reinforcement plate has been reinforced in the B-pillar.
Up to 04 / 99, the reinforcement plate in the B-pillar was fitted in a shorter
version.
The procedure for repair has thus fundamentally changed.
Replace cover for side member, left or right (partial replacement, B-pillar
before A-pillar and side panel, rear) (up to 04 / 99), refer to 41 11 300.

Cover for side member
B-pillar, inside
Front door
Rear door
Front seat
Front door and rear door edge trim
Front and rear entrance cover plates
Back seat and backrest
A- and B-pillar panelling
Safety belt with height adjustment
Front carpet (partially)
Left: Lower trim on instrument panel
Right: Glove compartment
dust must be removed or covered.

Measurement (A) = 220 mm from roof edge

Determine and mark inside B-pillar cutting line:

Measurement (A) = 50 mm from center of hole of upper seatbelt height
adjustment fixture.
Measurement (A) = 150 mm from center of bore.
Measurement (A) = 140 mm from center of bore for finishing strip,
entrance (1) with dia. 5.5 mm.
Measurement (B) = 140 mm from center of bore for panel for cover on
side member (2) with dia. 9.2 mm.
Caution!
Cut marked cutting lines on B-pillar and cover for side member.
Drill out welding spots for front and rear door openings.
Remove insulating mats in passenger compartment from cover for side
member.
Expose and open welding spots on underbody.
Expose welding spots on floor plate in area of cover for side member
from passenger compartment side.
Drill out welding spots of B-pillar on cover for side member from
At front seat carrier, drill out welding spots of bulkhead, cover for side
member, from passenger compartment side.
Caution!
Fire hazard!
Extract vapors and provide good ventilation.
Location of foam parts,
refer to 41 00 ... Arrangement of shaped parts for cavity bulkhead
Heat foam in following areas:
B-pillar
Side member cover, rear
Remove side member cover.
Straighten and grind connection points.

Remove foam residue from cavity sealing.
Determine and cut cutting lines on cover for side member spare part.
Determine outside B-pillar cutting line:
Measurement (A) = 50 mm from center of bore for finishing strip, entrance
(1) with dia. 5.5 mm.
Measurement (B) = 165 mm from center of bore for panel for cover on
side member (2) with dia. 9.2 mm.
Cut through marked cutting lines.
Make reinforcement plates from remaining metal sheet for center B-pillar.
Length of reinforcement plates approx. 40 mm.
Make reinforcement plates from remaining metal sheet for outside B-

pillar.
Length of reinforcement plates approx. 40 mm.
Drill holes for plug welding reinforcement plates on center of B-pillar.

Drill holes for plug welding reinforcement plates on outside of B-pillar.
Clean reinforcement plates and connection points on car and coat with
zinc dust paint.
Insert reinforcement plates on center of B-pillar at 1/2 length, secure in

position and weld up.
Insert reinforcement plates on outside of B-pillar at 1/2 length, secure in

position and weld up.
Grind welding spots until smooth.
Make reinforcement plates for cover for side member for connection
point
door pillar (A-pillar) and
C-pillar
from remaining metal sheet.
Width of reinforcement plates: approx. 60 mm.
Drill holes for plug welding reinforcement plates, connection point door
pillar (A-pillar) and C-pillar in body and cover for side member spare part.
Clean connection points at door pillar (A-pillar) and C-pillar on body and
cover for side member spare part and coat with zinc dust paint.
Fit reinforcement plate at door pillar (A-pillar) with 1/2 width in connection
points of body, locate in position and weld up.
Fit reinforcement plate at C-pillar with 1/2 width each in connection points
of body, locate in position and weld up.
Fit cover for side member spare part.

Mark holes for plug welding reinforcement plates.
Remove cover for side member spare part.
Cut expanded foam of cavity sealing on outside of B-pillar flush with metal
edge of B-pillar.
Install shaped parts for cavity sealing

B-pillar, inside (2),
entrance, center, inside (cover for side member) (1).

cover for side member
Install cover for side member spare part and locate in position. To install
cover for side member, also fit doors.
Weld cover for side member spare part in door aperture.Caution!

Do not weld upper welding spots on inside B-pillar (1) as the inside
B-pillar spare part would not then be able to be installed.
Weld reinforcement plate, cover for front side member.

Weld connection point, cover for front side member.
created.
Weld reinforcement plate, cover for rear side member.

Weld connection point, cover for rear side member.
created.
Weld reinforcement plates, outside B-pillar.
Weld connection point, outside B-pillar.
created.
Weld reinforcement plates, center B-pillar.

Weld connection point, center B-pillar.
created.
Weld cover for side member on underbody.
Caution!
Avoid overheating.
Extract vapors.
Weld welding spots of B-pillar on cover for side member from passenger
compartment side.
Caution!
Avoid overheating.
Extract vapors.
At front seat carrier, weld bulkhead, cover for side member, from
Cut inside B-pillar spare part.

Measurement (A) = 50 mm from center of hole of upper seatbelt height
adjustment fixture.
Fit inside B-pillar spare part.

reinforcement plate, inside B-pillar and
inside B-pillar spare part on cover for side member.
Make reinforcement plate from surplus sheet metal.
Drill holes in B-pillar for plug welding reinforcement plate.
Drill holes for plug welding reinforcement plate in spare part/B-pillar.
Clean connection faces on body and reinforcement plate and coat with
zinc dust paint.
Insert reinforcement plate (1) on inside B-pillar in body and weld up.
Drill holes for plug welding reinforcement plate, inside B-pillar, in spare
part.
Drill holes for plug welding inside B-pillar in cover for side member.
Clean connection faces on body and spare part and coat with zinc dust
paint.
Fit inside B-pillar spare part and locate in position.
Weld reinforcement plate, inside B-pillar.

Weld connection point, inside B-pillar.
created.
Caution!
Avoid overheating.
Extract vapors.
Weld holes for plug welding inside B-pillar in cover for side member.
Weld inside B-pillar to B-pillar.

While doing so, weld open spots of inside B-pillar in area of cover for side
member.
Grind down welded surfaces.Note:
Do not grind down welding seam thin in area of contact surface of
seatbelt height adjustment fixture.
Seatbelt height adjustment fixture must rest flat.
Coat connection face on outside B-pillar with tin and grind down.
Coat connection face of cover for front side member with tin and grind
down.
Coat connection face of cover for rear side member with tin and grind
down.
Seal connection points in passenger compartment.
If necessary, reinstall insulating material.
41 11 043 Replacing engine support front section on left (E46)
Instructions on body repair,

refer to 41Â 00
Place vehicle on straightening bench.

Complete bumper
Wheel arch trim
Radiator assembly
Front wall
Cover in wheel arch
Both headlight units
Auxiliary turn indicator light
Brake booster
Hood lock, left/right
Complete front axle with engine and transmission
Brake pipes
Other vehicle parts located in the repair zone or subject to be damaged
from heat, sparks or dust, must be removed or covered.
This work essentially corresponds to work step

41 11 044
Replacing engine support front section on right
This work is to be amended according to the details for the engine
support front section on left.
Caution!
The work steps specified in work step
41 11 044
Replacing engine support front section on right
alterations to the engine support

additional holes for plug welding
additional inert gas seams for lock at mating surfaces
must be carried out without delay in order to obtain a proper repair!
41 11 044 Replacing engine support front section on right

refer to 41 00

Complete bumper
Side wall, front
Wheel arch trim
Radiator assembly
Front wall
Cover in wheel arch
Both headlights, completely
Container for windscreen wash unit
Auxiliary turn indicator light
Hood lock, left/right
Complete front axle with engine and transmission
Battery, if necessary
Brake pipes
Air pump
If the engine support front section is replaced, it will also be necessary to

replace the bulkhead reinforcement.
Engine support front section.
Bulkhead reinforcement.
Expose engine support front section/wheel arch mating surface and drill
out welding spots.
Expose and clean bulkhead reinforcement connections in wheel arch.

Roughly cut open bulkhead reinforcement.
Remove insulating mat in passenger compartment and drill out bulkhead

reinforcement welding spots from passenger compartment side.
Remove bulkhead reinforcement.
From wheel arch side, expose and open welding spots and weld seams
engine support front section to engine support reinforcement
engine support front section to rear engine support
front wheel arch to engine support front section
From wheel arch side, expose and open welding spots and weld seams
engine support front section to engine support reinforcement
engine support front section to engine support rear section
carrier support to engine support
Caution!
When cutting, do not damage
engine support reinforcement

engine support rear section
wheel arch, front
Roughly cut open engine support front section before engine support
reinforcement since this remaining part (1) is removed separately.
Remove front section of engine support.
Mark out and cut separating point at carrier support on right.
A = approx. 120 mm from edge of carrier support.
B = approx. 15 mm from bore ∅ 7 mm.
Drill out welding spots of partial replacement carrier support.

Remove partial replacement carrier support on right.
Caution!
Do not damage engine support reinforcement when removing
remaining metal.
Remove remaining metal, engine support front section.

For this purpose, cut open welding spots with a chisel between engine
support reinforcement (2) and engine support front section (1).
View of both welding spots (3) at engine support reinforcement (2) and
engine support front section (1).
This is shown on spare part.
The arrow indicates the view from the passenger compartment, the
bulkhead in front is not visible!
Engine support reinforcement (2) is welded to bulkhead.
Remove further remaining metal.
Drill out engine support reinforcement (2) at new part engine support
front section (1).
Clean mating surfaces and drill holes for plug welding.
Caution!
To be able to carry out proper repairs, make following changes to
spare part engine support front section:
1.
To prevent grating noises, cut away flange (1) at engine support front
section drilled out from engine support reinforcement up to edge of
engine support outer shell (2).
The engine support front section must not contact the engine support
reinforcement on the vehicle.
Check this without fail.
The welding spots set here as standard can no longer be set in the
repairs!
2.
To achieve rigidity of the connection of the engine support front section
to the engine support reinforcement without the welding spots on the
removed flange, proceed as follows:
In the connection area to the engine support reinforcement (marked
area), drill additional holes on both sides for plug welding.
Make sure that additional holes for plug welding are likewise drilled on
both sides in area (1).
Caution!
Do not weaken component with too many holes!
For easier installation of engine support front section, bend up

flange of separating wall reinforcement (1)
edges of engine support rear section (2), (3).
Clean mating surfaces on vehicle and spare part and coat with zinc dust
paint.
Note:
For easier installation of engine support front section, remove
straightening support for stabilizer bar on engine support front
section completely from straightening bench.
Install spare part engine support front section at an angle from below; in
doing so, pay attention to bent flange of separating wall reinforcement.
Note:
Ensure sufficient clearance between cut engine support front
section and engine support reinforcement.
Clearance can be determined e.g. by placing sealing tape on cut
engine support front section and then installing and removing
engine support front section.
Sealing tape is then compressed to height which conforms to
engine support front section/engine support reinforcement
clearance.
Reinstall straightening support for stabilizer bar, secure engine support

front section in position with straightening angle set.
Bend back areas that have been bent open.
Realign mating surfaces.
Caution!
Secure engine support front section to mating surfaces with
additional inert gas seams.
Weld engine support front section on engine compartment side to

engine support reinforcement and to engine support rear section.
In doing so, secure engine support front section in marked areas to
mating surfaces with additional insert gas seams.
Caution!
Secure engine support front section to mating surfaces with
additional inert gas seams.
Weld engine support front section on wheel arch side to engine support
reinforcement and to engine support rear section.
In doing so, secure engine support front section in marked areas to
mating surfaces with additional insert gas seams.
Weld engine support front section to wheel arch and to separating wall
reinforcement.
Weld engine support front section to engine support rear section.
Drill holes for plug welding bulkhead reinforcement.

Clean and coat joint surfaces with zinc dust paint.
Install bulkhead reinforcement in wheel arch and weld.
Weld bulkhead reinforcement from passenger compartment side.
Weld bulkhead reinforcement in assembly compartment.
Step down bulkhead carrier support.
Note:
Take into account step dimension for bulkhead carrier support
partial replacement.
Make bulkhead carrier support partial replacement from bulkhead carrier

support spare part.
A = approx. 120 mm from edge of bulkhead carrier support
+ step dimension X
B = approx. 15 mm from bore ∅ 7 mm +
step dimension X
Drill holes for plug welding.
Clean and coat joint surfaces with zinc dust paint.
Grind welded seam of engine support front section on mating surface of
bulkhead carrier support partial replacement.
Remove as little material as possible, do not grind thin!
Clean mating surfaces for bulkhead carrier support partial replacement
and coat with zinc dust paint.
Install bulkhead carrier support partial replacement, secure in position

and weld.
Grind all mating surfaces.

Follow instructions for body repairs.

For stripping and rigging operations, refer to texts on KSD CD (FR
number 41 11 400).
Open weld joints in areas (1).
Open weld joints in area (1).

Remove carrier plate (2).
Open weld joints in area (1) under removed carrier plate.
Open weld joints in area (1) in right wheel arch.

View from vehicle interior:
Remove anti-drumming lining in area (1) and open weld joints.
Remove anti-drumming lining in area (2).
View from luggage compartment:

Open welding spots in areas (1) on new rear axle carrier part.
Drill all connection points on carrier plate (2) for plug welding.
Open all weld joints in areas (3) and drill for plug welding.
Drill areas (1) for plug welding.

Take off holder (1).
Clean all connecting points on new part and body and coat with welding
primer.
Adjust rear axle carrier to fit with straightening attachment.
Plug-weld area (1).
Adjust carrier plate (2) to fit.

Plug-weld areas (1).
Plug-weld area (1).
Plug- or spot-weld areas (1).
Plug-weld area (1).

Plug-weld area (1).

Reattach removed anti-drumming linings.
Seal all seams on body.
41 11 029 Replacing right engine support (partial replacement in front of
front axle) (E46)

refer to 41 00

Cover in wheel arch
Complete bumper
Front wall
Radiator assembly
Container for windscreen wash unit
Other vehicle parts located in the repair zone or subject to be damaged
from heat, sparks or dust, must be removed or covered.
Mark cutting line and cut off engine carrier.

Cutting line is located in center of oval bore.
Length (A) of oval bore: 15 mm
Height (B) of oval bore: 12 mm
Cut off new engine carrier to match cut on car and fit in.
Clean mating surfaces and drill holes for plug welding.
Clean engine carrier connection and drill holes for plug welding.
Produce reinforcement plates with width (B) of about 60 mm and coat with
zinc dust paint.
Insert reinforcement plates half their width into engine carrier and plug
weld.
Align partial replacement piece with straightening attachment (1) and plug
weld.
Weld engine carrier in welding joint.
Grind down and clean welded seam and welded spots.
Tin out and grind joint until it is smooth.
41 12 535 Replacing complete rear luggage compartment floor (tail panel
removed) (E46)
Instructions for body repair

Refer to 41 00.
Rear trunk floor panel, complete

Fuel tank
Rear axle carrier
Expose mating surface, luggage compartment floor/side wall, left and

right.
Note:
Do not damage metal panels underneath!
Roughly cut side member at bore dia. 16 mm.
Drill off welding spots in area of spare wheel recess.
Expose mating surface, luggage compartment floor/floor assembly.

Cut through trunk floor roughly.Important!

Do not damage connecting parts (e.g. cross-members) and
underlying metal sheets.
Roughly cut connection for side member on left.
Note:
Light arrow points in direction of travel.
1 = Old part, luggage compartment floor

2 = Floor assembly
3 = Mating surface, luggage compartment floor/floor assembly
Roughly cut connection for side member on right.

Note:
1 = Old part, luggage compartment floor

2 = Floor assembly
3 = Mating surface, luggage compartment floor/floor assembly
Remove scrap metal. Straighten and grind joint surfaces.
Fit in trunk floor plate with straightening attachment and clamp.

Note:
Mark out holes for plug welding in area of spare wheel recess (1) on
account of impressions from underside.

spare wheel recess area (1)
wheel arch extension (2)
floor assembly (3)
Remove trunk floor.
Drill holes in new trunk floor plate for plug welding.
Coat mating surfaces on luggage compartment floor spare part and on
car with zinc dust paint.
Installation:
Carry over the work step shown symmetrically to the other side of the
vehicle.
Clip shaped parts into areas (1) and bond with window adhesive.
Fit in trunk floor plate with straightening attachment and clamp.

Weld luggage compartment floor to mating surface, floor assembly.
Weld luggage compartment floor in area of spare wheel recess.

Weld left side member in luggage compartment floor.
Note:
Accessibility for welded seam between right side member and right
wheel arch interior greatly restricted.
Measurement (A) = approx. 25 mm
Weld right side member in luggage compartment floor.
Weld left side member and luggage compartment floor to

underside.Note:
Weld right side member and luggage compartment floor to

underside.Note:
Weld mating surface, luggage compartment floor/side wall and left wheel
arch.
Weld mating surface, luggage compartment floor/side wall and right wheel
arch.
Grind down mating surfaces.
.

(1) A-pillar,
refer to 41 00 ...
refer to 41 00 ...
refer to 41 00 ...
refer to 41 00 ...
refer to 41 00 ...
refer to 41 00 ...

refer to 41 00 ...
(8) Entrance, rear,
refer to 41 00 ...
refer to 41 00 ...
B-pillar, inner,
refer to 41 00 ...
refer to 41 00 ...
refer to 41 00 ...

Caution!
shaped part!
Caution!
Note:

Further work,
side member
Caution!
spray can!
Use by date on can.
of BMW AG.
Substrate must be
clean and free from
dust,
grease,
Note:
of 1 hour.
side member

Further scopes,
paint etc.).
Caution!
relative humidity.
Note:
Caution!
Caution!
Parts Service
.
to engage.

necessary.

Remove shaped part.
- 100 grain).

Locate shaped part.



Caution!

41 14 511 Replacing complete rear left wheel arch
Work instructions:
Refer to 41 00 ... Notes on body repairs.
This repair operation involves replacing the following components:

Reinforcement, side section
Outer section of rear wheel arch
Wheel arch inner section, rear
Determine and mark out side panel reinforcement cutting line.

Measurement (A) = 50 mm from center of bore dia. 12 mm.
Caution!
Course of sunroof water drainage pipe in side panel reinforcement.
Caution!
Carefully cut side panel reinforcement.
Do not damage sunroof water drainage pipe.
Note:
Possibility of repair for water drainage pipe, slide/tilt sunroof, through
hose, refer to BMW Parts Service.
Drill out welding spots for side panel reinforcement on

outer section of wheel arch
door opening
rear window frame.
Open welding spots for sunroof water drainage pipe holder (1,2).
Expose and drill out welding spots on wheel arch extension.

Expose opening for sunroof water drainage pipe in wheel arch extension.
Caution!
Cut through clips for securing cavity sealing (foam).

Heat side panel reinforcement in area of cavity sealing (foam).
Remove reinforcement for side section.
Note:
Cavity sealing (foam) is held back by sunroof water drainage pipe
on body.
Remove foam (1).

Do not damage sunroof water drainage pipe (2).
Remove foam.
Expose connection points, outer wheel arch section/inner wheel arch
section, in wheel arch.
Drill out welding spots for connection points, outer wheel arch section, at
door opening
inner wheel arch section.
Drill out connection point, rear panel and rear parcel shelf.
Drill out connection point, inside C-pillar.

Drill out welding spots on connection point, cover for inside side
member/outer wheel arch section.
Caution!
Remove outer section of wheel arch.
Remove remaining metal at connection point

rear panel
rear parcel shelf.

inside rear parcel shelf
inside C-pillar.
Expose connection points, inner wheel arch section.

Note:
Do not damage closing plate, cover for side member, to remain on
body.
Roughly cut out inner wheel arch section and remove.

Closing plate, cover for side member (1), remains on body.
Roughly cut connection point, inner wheel arch section/closing plate,
cover for side member.
Drill out welding spots, inner wheel arch section, at closing plate, cover
for side member.
Remove scrap metal.

Drill out welding spots on closing plate, cover for inside side member (1).
Remove closing plate (2) from inner wheel arch section spare part.
Straighten and grind connection face.
Fit inner wheel arch section and locate in position.
Note:
Use straightening attachment.
Mark connection faces.

Mark out holes for plug-welding.
Remove inner wheel arch section.

Drill holes for plug welding.
Clean connection faces.

Clean connection faces on spare part and on car and coat with zinc dust
paint.
Install inner wheel arch section and locate in position.Note:

Use straightening attachment.
Weld inner wheel arch section.Note:
After removing straightening attachment, weld connection faces that
were covered by straightening attachment.
Remove straightening attachment.

Weld up inner wheel arch section completely.
Fit spare wheel arch outer section and secure.

Mark holes for plug welding inside C-pillar.
Remove outer wheel arch section spare part.
Drill holes for plug welding inside C-pillar.

Clean connecting faces and coat with zinc dust paint.
Coat connection faces for outer wheel arch section on body with zinc
dust paint.
Adjust spare part to fit and secure.
Weld outer wheel arch section at

door opening
Weld connection point, rear panel and rear parcel shelf.
Weld connection point, inside C-pillar.
Weld connection point, cover for inside side member/outer wheel arch
section.
Make C-pillar reinforcement spare part.

If necessary, drill out sunroof water drainage pipe.
Measurement (A) = measured from center of bore dia. 12 mm.
Note:
Note relief measurement.
Measurement (A) = 50 mm - relief measurement.
Cut and relieve side panel reinforcement spare part.
When fitting side panel reinforcement, make sure sunroof water drainage
pipe (2) is seated in wheel arch extension (1).
Fit side panel reinforcement spare part.

The sunroof water drainage pipe must not be touching at any point
otherwise there would be scraping and grinding noises.
Mark holes for plug welding on body.
Remove the replacement part.
Drill holes for plug welding on body.
Clean connection faces on side panel reinforcement spare part and on
body and coat with zinc dust paint.
Install shaped part for cavity sealing, inside C-pillar.

Procedure and materials,
refer to 41 00 ... Installing shaped parts for cavity sealing, except cover
for side member
Short summary:
Place shaped part for cavity sealing (1) on car and mark out contact
surface on body and on sunroof water drainage pipe.
Shaped part for cavity sealing is underneath sunroof water drainage pipe
(2).
Remove shaped part for cavity sealing and clean contact surface (1) on
car.
Clean contact surface on sunroof water drainage pipe (2).
(2).
Place shaped part for cavity sealing (1) on side panel reinforcement
spare part and mark out connection face.
Remove shaped part for cavity sealing and clean connection face on
spare part.
Grind connection faces on car and spare part, clean and coat with zinc
dust paint.
Apply window adhesive approx. 20 mm high to connection face (1) on
side panel reinforcement spare part.
1 = Bores for clips for securing shaped part to cavity sealing.

body and to sunroof water drainage pipe.
Fitting shaped part for cavity sealing on cars with slide/tilt sunroofs:
Clean shaped part for cavity bulkhead.

(2).
Fit shaped part for cavity sealing (1) on body.
Apply window adhesive approx. 20 mm high to shaped part for cavity
sealing and to sunroof water drainage pipe.
Install side panel reinforcement spare part and locate in position.

Note:
During installation, make sure the clips are passed through the
bores provided.
Pull clips with pliers through bores until they are locked.
The clips serve to secure the shaped part for the cavity sealing to the
side panel reinforcement.
Fitting shaped part for cavity sealing on cars without slide/tilt sunroofs:
Mount shaped part for cavity sealing (1) on side panel reinforcement
spare part.
Apply window adhesive approx. 20 mm high to foam section on contact
surface of spare part.
Fit spare part and locate in position.
Note:
bores provided.
Note:
On cars without slide/tilt sunroof, fill opening for sunroof water
drainage pipe in shaped part for cavity sealing with window
adhesive.
For additional treatment of cavity sealing, fill cavity through bore with 2K
foam (refer to BMW Parts Service),
refer to 41 00 ... Installing cavity sealing with cavity foam.
Weld side panel reinforcement at
door opening
rear window frame.
Weld holder, sunroof water drainage pipe (2).
Do not weld holder, sunroof water drainage pipe (1), yet.
Weld connection point for wheel arch extension.
Set up sunroof water drainage pipe so that it passes between outer

wheel arch section and C-pillar reinforcement.
Weld holder, sunroof water drainage pipe.
Perform plug welding at side panel reinforcement in area of connection

point (1).
At connection point of C-pillar (2), arrange individual welding spots so
tightly as to create an enclosed seam.
Caution!
Locate welding spots in a way which prevents distortion caused by
heat elongation. Ensure that welded areas have cooled down
sufficiently.
As for side panel reinforcement, make sure sunroof water drainage pipe
(2) is seated in opening in wheel arch extension (1) without resting on
any point.

Seal opening for sunroof water drainage pipe in wheel arch extension.
41 14 531 Replacing engine support side frame connection, front left
Prerequisite
Left engine support removed.
- Observe the procedure for repair stage 3.
For additional information see: 41 00 ... Repair method for repair stage 3
- For information about stripping and rebuilding operations, refer to the surrounding text of the KSD. See the flat rate
unit number.
Links
General repair instructions Used in step
41 14 031 Replacing front right wheel arch
Notes on body repairs,

refer to 41 00.
Wheel arch, front right
Remove or loosen following parts:

Spring strut shock absorber
Front door
Front trim
Front wall
Front lid
Side wall, front
Note:
In the front wheel arch spare part, there is no bore (2) for the centering
pin (1) of the spring strut support bearing!
The bore (2) for the centering pin is made on the complete vehicle in
series production and is therefore not present in the spare part.
Installation:
Remove centering pin (1) on spring strut support bearing or, for ”rough
road package” suspension, on spacer ring (A) before installation in a
wheel arch without centering bore (e.g. strike off or sever).
Caution!
Avoid damage to adjacent sheet metal parts.
Expose and cut connection points on engine support and firewall.
Expose and cut connection point, cover A-pillar/wheel arch.
Drill out welding spots on support carrier at top.

Determine and mark out partition area at connection, partial replacement
piece support carrier, top.
Measurement (A) = approx. 120 mm from center of bore ( ∅ 8 mm) for
securing side wall.
Drill out welding spots at connection point, support plate/A-pillar, outer.

Caution!
Do not damage flange for support carrier at firewall extension.
Roughly cut out support carrier and remove.
Expose mating surfaces.

Drill out cover, A-pillar.
Expose and cut connection point, endplate/wheel arch.
Expose and drill out welding spots, spring strut extension.

Remove wheel arch.
Remove sealing material and residual metal sheeting from connection
points.
Determine and mark out partition area at connection, partial replacement

piece support carrier, top.
Measurement (A) = approx. 120 mm from center of bore ( ∅ 8 mm) for
securing side wall.
Cut support carrier partial replacement piece.
Fit front wheel arch and locate in position.

cover, A-pillar, inside
connection point, wheel arch/firewall
connection point, wheel arch/endplate
connection point, firewall extension/support carrier, top.
Remove front wheel arch.
Drill holes for plug welding in wheel arch partial replacement piece and
clean connection points:
Cover, A-pillar, inside
Connection point, wheel arch/firewall
Connection point, wheel arch/endplate
Connection point, firewall extension/support carrier, top
Coat all connection points on body and wheel arch partial replacement
piece with zinc dust paint.
Make reinforcement plate from remaining metal sheet, support carrier
partial replacement piece.
Width approx. 40 mm.
Drill holes for plug welding reinforcement plate and fit reinforcement plate.
Coat connection point, body and reinforcement plate, with zinc dust paint.
Weld reinforcement plate and grind welding joints.
Install straightening bench support for wheel arch.

Fit front wheel arch to straightening bench and secure in position.
Carry out plug welding at following points:

Cover, A-pillar, inside
Connection point, wheel arch/endplate
Note:
For purposes of clarity, straightening bench support for wheel arch
shown removed.
Carry out plug welding at extension, firewall/support carrier, top.
Weld up connection point, support carrier partial replacement piece.
Weld up connection point, wheel arch/engine mount.
Weld up connection point, firewall/wheel arch.

Weld up spring strut reinforcement to engine mount.
Weld up cover, A-pillar, and support plate, A-pillar, outside.

Grind down mating surfaces.
41 14 502 Replacing outer section of left or right rear wheel housing (side
panel removed)
Work instructions:
Refer to 41 00 ... Notes on body repairs.
This repair operation involves replacing the following components:

Reinforcement, side section
Outer section of rear wheel arch

Spring strut shock absorber
Measurement (A) = 50 mm from center of bore dia. 12 mm.
Caution!
Course of sunroof water drainage pipe in side panel reinforcement.
Caution!
Carefully cut side panel reinforcement.
Note:
Drill out welding spots for side panel reinforcement on

door opening
rear window frame.
Open welding spots for sunroof water drainage pipe holder (1,2).
Expose and drill out welding spots on wheel arch extension.
Expose opening for sunroof water drainage pipe in wheel arch extension.
Caution!
Cut through clips for securing cavity sealing (foam).

Heat side panel reinforcement in area of cavity sealing (foam).
Remove reinforcement for side section.
Note:
Cavity sealing (foam) is held back by sunroof water drainage pipe
on body.
Remove foam (1).

Do not damage sunroof water drainage pipe (2).
Remove foam.
Expose connection points, outer wheel arch section/inner wheel arch

section, in wheel arch.
Drill out welding spots for connection points, outer wheel arch section, at
door opening
Drill out connection point, rear panel and rear parcel shelf.
Drill out connection point, inside C-pillar.
Drill out welding spots on connection point, cover for inside side
member/outer wheel arch section.
Caution!
Remove outer section of wheel arch.

inner wheel arch section
rear panel
rear parcel shelf.
Coat contact surfaces on car with zinc dust paint.

inside rear parcel shelf
inside C-pillar.
Coat contact surfaces on car with zinc dust paint.
Fit spare wheel arch outer section and secure.
Mark holes for plug welding inside C-pillar.
Remove outer wheel arch section spare part.
Drill holes for plug welding inside C-pillar.

Adjust spare part to fit and secure.
Weld outer wheel arch section at

door opening
Weld connection point, rear panel and rear parcel shelf.
Weld connection point, inside C-pillar.

Weld connection point, cover for inside side member/outer wheel arch
section.
Make C-pillar reinforcement spare part.

If necessary, drill out sunroof water drainage pipe.

Measurement (A) = measured from center of bore dia. 12 mm.
Note:
Note relief measurement.
Measurement (A) = 50 mm - relief measurement.
Cut and relieve side panel reinforcement spare part.

When fitting side panel reinforcement, make sure sunroof water drainage
pipe (2) is seated in wheel arch extension (1).
Fit side panel reinforcement spare part.

Mark holes for plug welding on body.
Remove the replacement part.
Drill holes for plug welding on body.

Clean connection faces on side panel reinforcement spare part and on
body and coat with zinc dust paint.
Install shaped part for cavity sealing, inside C-pillar.

refer to 41 00 ... Installing shaped parts for cavity bulkhead, except cover
for side member
Short summary:
Place shaped part for cavity sealing (1) on car and mark out contact
surface on body and on sunroof water drainage pipe.
(2).
Remove shaped part for cavity sealing and clean contact surface (1) on
car.
Clean contact surface on sunroof water drainage pipe (2).
(2).
Place shaped part for cavity sealing (1) on side panel reinforcement
spare part and mark out connection face.
Remove shaped part for cavity sealing and clean connection face on
spare part.
Grind connection faces on car and spare part, clean and coat with zinc
dust paint.

side panel reinforcement spare part.
1 = Bores for clips for securing shaped part to cavity sealing.

body and to sunroof water drainage pipe.
Fitting shaped part for cavity sealing on cars with slide/tilt sunroofs:
Clean shaped part for cavity bulkhead.
Shaped part for cavity bulkhead (1) is behind water drainage pipe for
sunroof (2).
Fit shaped part for cavity sealing (1) on body.
Apply window adhesive approx. 20 mm high to shaped part for cavity
sealing and to sunroof water drainage pipe.
Install side panel reinforcement spare part and locate in position.

Note:
bores provided.
Fitting shaped part for cavity sealing on cars without slide/tilt sunroofs:
Mount shaped part for cavity sealing (1) on side panel reinforcement
spare part.
Apply window adhesive approx. 20 mm high to foam section on contact
surface of spare part.
Fit spare part and locate in position.
Note:
bores provided.
Note:
On cars without slide/tilt sunroof, fill opening for sunroof water
drainage pipe in shaped part for cavity sealing with window
adhesive.
For additional treatment of cavity sealing, fill cavity through bore with 2K
foam (refer to BMW Parts Service),
refer to 41 00 ... Installing cavity sealing with cavity foam.
Weld side panel reinforcement at

door opening
rear window frame.
Weld holder, sunroof water drainage pipe (2).
Do not weld holder, sunroof water drainage pipe (1), yet.
Weld connection point for wheel arch extension.
Set up sunroof water drainage pipe so that it passes between outer

wheel arch section and C-pillar reinforcement.
Weld holder, sunroof water drainage pipe.
Perform plug welding at side panel reinforcement in area of connection
point (1).
At connection point of C-pillar (2), arrange individual welding spots so
tightly as to create an enclosed seam.
Caution!
sufficiently.
As for side panel reinforcement, make sure sunroof water drainage pipe
(2) is seated in opening in wheel arch extension (1) without resting on
any point.

Seal opening for sunroof water drainage pipe in wheel arch extension.
.

(1) A-pillar,
refer to 41 00 ...
refer to 41 00 ...
refer to 41 00 ...
refer to 41 00 ...
refer to 41 00 ...
refer to 41 00 ...

refer to 41 00 ...
(8) Entrance, rear,
refer to 41 00 ...
refer to 41 00 ...
B-pillar, inner,
refer to 41 00 ...
refer to 41 00 ...
refer to 41 00 ...

Caution!
shaped part!
Caution!
Note:

Further work,
side member
Caution!
spray can!
Use by date on can.
of BMW AG.
Substrate must be
clean and free from
dust,
grease,
Note:
of 1 hour.

Further scopes,
paint etc.).
Caution!
relative humidity.
Note:
Caution!
Caution!
Parts Service
.
Caution!
Burn hazard!


Caution!
Burn hazard!

side member

Further scopes,
paint etc.).
Caution!
relative humidity.
Note:
Caution!
Caution!
Parts Service
.
to engage.

necessary.

Remove shaped part.
- 100 grain).

Locate shaped part.



Caution!

41 21 510 Replacing front left door column (partial replacement) (front side
panel removed)

Door pillar (A-pillar)
Connecting plate, side frame
Sealing, connection, side frame
Remove following parts or loosen them:

Dashboard trim panel
Front seat
windshield
A-pillar finisher
Caution!
Remove or cover up other vehicle components in the repair zone
which are at risk from heat, flying sparks and dust.
Determine and mark upper cowl panel cutting line.

Measurement (B) = 90 mm from center of bore for trim strip.
1 = Roof edge
2 = Bore for trim strip
Expose and drill out welding spots in windshield frame.
Assembly, cowl panel:

1 = Water drainage pipe, slide/tilt sunroof
2 = Reinforcement, cowl panel
3 = Cowl panel
Caution!
Carefully cut cowl panel.
Note:
Define separating point in cover for side member and mark out.
Measurement (A) = 25 mm from 2nd bore for finishing strip, entrance.
Drill out welding spots in door opening.
Drill out welding spots on door pillar (A-pillar), inside, in upper area of door
retaining strap.
Drill out welding spots on door pillar (A-pillar), inside, in lower area of door
retaining strap.
Clean connection face at cover for side member from interior.
Open weld seams on cover for side member for door pillar (A-pillar) from
interior.
Expose and open welding spots on floor plate.
Open weld seam on connection point, windshield frame/door pillar.

Drill out welding spots on connecting plate, side frame, and acoustic
baffle, connection, side frame.
Remove acoustic baffle, connection, side frame.
Drill out welding spots on connecting plate, side frame.

Remove connecting plate, side frame.
Drill out connection points, door pillar (A-pillar) on body, inside, in area of
door opening of door retaining strap.
At door hinge, top, cut open door pillar and open welding spot.
Caution!
Fire hazard!
Note:
The sunroof water drainage pipe is secured in position by a foam
jacket in the body.
To facilitate removal, the area around the foam surface can be
heated gently.
Foam jacket, sunroof water drainage pipe, in body.
Remove door pillar (A-pillar)

Remove scrap metal.
Remove adhesive residue.
In vehicles before 6/2002 drill out reinforcement (1).

Reinforcement has been modified and is now located in the spare part.
Mark out and cut partition area for door pillar spare part for cowl panel,
top.
1..4 = Bores for trim strip
Measurement (A) = 80 mm from 4th bore for trim strip.
Mark out and cut partition area for door pillar spare part for cover for side
member.
Make reinforcement plate from remaining metal sheet for cowl panel
connection, top.
Make reinforcement plate from remaining metal sheet for cover

connection for side member.
Coat connection faces on reinforcement plate and body with zinc dust
paint.
At door pillar spare part (A-pillar), clean connection faces and coat with
zinc dust paint.
Drill holes for plug welding at reinforcement plates, connection point, cowl
panel, top, and cover for side member.
At door pillar spare part (A-pillar), clean connection faces and coat with
zinc dust paint.
Fit reinforcement plates, cowl panel, top and cover for side member with
1/2 width each in connection points of body, locate in position and weld
up.
Install shaped part for cavity acoustic baffle, cowl panel, top:
refer to 41 00 ... Installing shaped parts for cavity acoustic baffle, except
cover for frame member
Short summary:
Gently bend open retaining lug (1) for securing shaped part so that
shaped part can be attached.
Clean bearing surface (2) of shaped part for cavity acoustic baffle on
body and on door pillar (A-pillar) spare part.
Clean shaped part for cavity acoustic baffle (1).

Coat shaped part for cavity baffle (1) with recommended window
adhesive and attach with lug (2) to retaining lug (3).
Bend back retaining lug with shaped part for cavity acoustic baffle up to
bearing surface on door pillar (A-pillar) spare part.
Shaped part for cavity acoustic baffle must be positioned 90° to plate of
door pillar (A-pillar).
Check sealing with window adhesive; if necessary, reseal with window
adhesive.
Then place window adhesive on shaped part for cavity acoustic baffle.
Installing shaped part for cavity sealing, sunroof water drainage pipe:
refer to 41 00 ... Installing shaped parts for cavity acoustic baffle, except
cover for frame member
Short summary:
Cut off lug.
Protect polished areas against rust.
Clean bearing surface of shaped part for cavity acoustic baffle on body
and on door pillar (A-pillar) spare part.
Clean shaped part for cavity sealing.

Coat shaped part for cavity acoustic baffle with recommended window
adhesive.
Install shaped part for cavity acoustic baffle in door pillar (A-pillar) spare
part.
Check sealing with window adhesive; if necessary, reseal with window
adhesive.
Then apply window adhesive to shaped part for cavity sealing and
opening for sunroof water drainage pipe.
Coat contact surface of shaped part for cavity sealing on sunroof water
drainage pipe with recommended window adhesive so as to guarantee a
complete seal.
Remove door pillar (A-pillar), locate in position and weld up.
Weld up reinforcement plates.
At connection point
Cowl panel, side, top
Cover for side member
arrange individual welding spots so tightly together that a sealed seam is
created.
Grind down welding surfaces on connection points of door pillar (A-pillar).

Coat connection point, cowl panel, top, and cover for side member with
tin and grind down.
Note:
Carefully seal sunroof water drainage pipe so as to prevent water
from leaking into passenger compartment!
Seal sunroof water drainage pipe with window adhesive.
Fit side frame connecting plate and mark out holes for plug welding.
Remove connecting plate, side frame.
Drill holes for plug welding connecting plate, side frame.
Clean connection faces on connecting plate, side frame, and on body

and coat with zinc dust paint.
Fit side frame connecting plate, locate in position and weld up.
Fit acoustic baffle, connection, side frame, and mark out holes for plug
welding.
Remove acoustic baffle, connection, side frame, and drill holes for plug
welding.
Clean connection faces on acoustic baffle, connection, side frame, and
on body and coat with zinc dust paint.
Fit acoustic baffle, connection, side frame, locate in position and weld up.
41 32 000 Replacing left or right cowl panel (partial replacement in front of
roof connection)
The cowl panel spare part must be made as required from the roof frame.

Front seat
Windshield
A-pillar finisher
Caution!

1 = Roof edge
Determine and mark out lower cowl panel partition area.
Measurement (A) = 405 mm from center of penultimate bore for trim strip
Expose connection point in windshield frame and drill out welding spots.

1 = Partition area, lower cowl panel
2 = Partition area, upper cowl panel

3 = Cowl panel
Caution!
Do not damage water drainage pipe for slide/tilt sunroof.
Note:
Caution!
Fire hazard!
Heat foam area and remove cowl panel.


Remove foam residue (1) from cavity bulkhead.
Mark out and cut partition areas (top/bottom) on cowl panel spare part.
Make reinforcement plate from remaining metal sheet for connection, top.
Make reinforcement plate from remaining metal sheet for connection,

bottom.
Fit cut cowl panel spare part.

Clean connection faces and coat reinforcement plates (top/bottom) with
zinc dust paint.
Drill holes for plug welding on cowl panel (top/bottom).

Drill holes for plug welding on cowl panel spare part (top/bottom).
Fit reinforcement plates (top/bottom), locate in position and weld up.

Coat connection faces on body and coat with zinc dust paint.
Install shaped part for cavity bulkhead, cowl panel, side, top.
for side member
Short summary:
Clean bearing surface of shaped part for cavity bulkhead on body and on
cowl panel spare part.
1 = Lug for securing shaped part
Clean shaped part for cavity bulkhead (2).
Coat shaped part for cavity bulkhead (2) with recommended window
adhesive and attach to retaining lug (1).
Installation:
Shaped part for cavity bulkhead (1) must be positioned 90Â° to
plate of door pillar (2).
Then place window adhesive on shaped part for cavity bulkhead.
Fit cut cowl panel spare part and locate in position.

At connection point at top and bottom, arrange individual welding spots
so tightly as to create an enclosed seam.
Caution!
sufficiently.
Weld up connecting points in door aperture.

Weld up connection point, windshield frame.

Coat connection point, cowl panel, top and bottom, with tin and grind
down.

number 41 11 400).




primer.
Plug-weld area (1).

Plug-weld area (1).
Plug-weld area (1).

Plug-weld area (1).

.

(1) A-pillar,
refer to 41 00 ...
refer to 41 00 ...
refer to 41 00 ...
refer to 41 00 ...
refer to 41 00 ...
refer to 41 00 ...

refer to 41 00 ...
(8) Entrance, rear,
refer to 41 00 ...
refer to 41 00 ...
B-pillar, inner,
refer to 41 00 ...
refer to 41 00 ...
refer to 41 00 ...

Caution!
shaped part!
Caution!
Note:

Further work,
side member
Caution!
spray can!
Use by date on can.
of BMW AG.
Substrate must be
clean and free from
dust,
grease,
Note:
of 1 hour.
side member

Further scopes,
paint etc.).
Caution!
relative humidity.
Note:
Caution!
Caution!
Parts Service
.
to engage.

necessary.

Remove shaped part.
- 100 grain).

Locate shaped part.



Caution!

.

(1) A-pillar,
refer to 41 00 ...
refer to 41 00 ...
refer to 41 00 ...
refer to 41 00 ...
refer to 41 00 ...
refer to 41 00 ...

refer to 41 00 ...
(8) Entrance, rear,
refer to 41 00 ...
refer to 41 00 ...
B-pillar, inner,
refer to 41 00 ...
refer to 41 00 ...
refer to 41 00 ...

Caution!
shaped part!
Caution!
Note:

Further work,
side member
Caution!
spray can!
Use by date on can.
of BMW AG.
Substrate must be
clean and free from
dust,
grease,
Note:
of 1 hour.
side member

Further scopes,
paint etc.).
Caution!
relative humidity.
Note:
Caution!
Caution!
Parts Service
.
to engage.

necessary.

Remove shaped part.
- 100 grain).

Locate shaped part.



Caution!

41 31 010 Replacing roof panel (models with slide/tilt sunroof)
Read contents of Body, General.
Remove and/or loosen following components:

Windscreen
Rear window
Roof liner
Sun roof
If necessary, rear parcel shelf
Wiring harness (partially)
Note:
In the area of the windscreen frame, the slide/tilt sunroof
reinforcement of the roof outer skin is additionally bonded with the
windscreen frame!
When replacing the roof outer skin, this bonding must be re-
established!
View of bonding of slide/tilt sunroof reinforcement of roof outer skin /

windscreen frame from passenger compartment.
(1) = Windscreen frame
(2) = Adhesive layer
(3) = Slide/tilt sunroof reinforcement of roof outer skin
Observe bonding specifications for body components.
Installation:
Complete all weld joints and brazed joints as standard on the new
component.
In event of lack of accessibility, replace welding spots with MAG plug
welds.
.

(1) A-pillar,
refer to 41 00 ...
refer to 41 00 ...
refer to 41 00 ...
refer to 41 00 ...
refer to 41 00 ...
refer to 41 00 ...

refer to 41 00 ...
(8) Entrance, rear,
refer to 41 00 ...
refer to 41 00 ...
B-pillar, inner,
refer to 41 00 ...
refer to 41 00 ...
refer to 41 00 ...

Caution!
shaped part!
Caution!
Note:

Further work,
side member
Caution!
spray can!
Use by date on can.
of BMW AG.
Substrate must be
clean and free from
dust,
grease,
Note:
of 1 hour.
side member

Further scopes,
paint etc.).
Caution!
relative humidity.
Note:
Caution!
Caution!
Parts Service
.
to engage.

necessary.

Remove shaped part.
- 100 grain).

Locate shaped part.



Caution!

41 32 000 Replacing left or right cowl panel (partial replacement in front of
roof connection)
The cowl panel spare part must be made as required from the roof frame.

Front seat
Windshield
A-pillar finisher
Caution!

1 = Roof edge
Determine and mark out lower cowl panel partition area.
Measurement (A) = 405 mm from center of penultimate bore for trim strip
Expose connection point in windshield frame and drill out welding spots.


3 = Cowl panel
Caution!
Do not damage water drainage pipe for slide/tilt sunroof.
Note:
Caution!
Fire hazard!
Heat foam area and remove cowl panel.


Remove foam residue (1) from cavity bulkhead.
Mark out and cut partition areas (top/bottom) on cowl panel spare part.
Make reinforcement plate from remaining metal sheet for connection, top.
Make reinforcement plate from remaining metal sheet for connection,

bottom.
Fit cut cowl panel spare part.

Clean connection faces and coat reinforcement plates (top/bottom) with
zinc dust paint.
Drill holes for plug welding on cowl panel (top/bottom).

Drill holes for plug welding on cowl panel spare part (top/bottom).
Fit reinforcement plates (top/bottom), locate in position and weld up.

Coat connection faces on body and coat with zinc dust paint.
Install shaped part for cavity bulkhead, cowl panel, side, top.
for side member
Short summary:
Clean bearing surface of shaped part for cavity bulkhead on body and on
cowl panel spare part.
1 = Lug for securing shaped part
Clean shaped part for cavity bulkhead (2).
Coat shaped part for cavity bulkhead (2) with recommended window
adhesive and attach to retaining lug (1).
Installation:
Shaped part for cavity bulkhead (1) must be positioned 90Â° to
plate of door pillar (2).
Then place window adhesive on shaped part for cavity bulkhead.
Fit cut cowl panel spare part and locate in position.

At connection point at top and bottom, arrange individual welding spots
so tightly as to create an enclosed seam.
Caution!
sufficiently.
Weld up connecting points in door aperture.

Weld up connection point, windshield frame.

Coat connection point, cowl panel, top and bottom, with tin and grind
down.
41 33 040 Replacing front left or right side wall holder
Note:
Side wall removed.
Transfer the systematic diagram onto the respective holder version.
Procedure Observe repair stage 2!
Following new body parts are required (refer to Electronic Parts

Catalogue):
(1) Holder, side wall, front (variant 1)
Following consumables are required:
Material Quantity
Adhesive K5a 1
Blind rivets N3 2
Cleaning agent R1 1
Removal of side wall holder (variant 1):
Release welded connections in areas (1) and remove holder (2).
Preparation of new part:

Adjust new part in conjunction with side panel in front to fit.
In area of bonding surfaces (1), set 2 4.2 mm dia. bore holes (2) for blind
rivetsN3.
Remove new part and deburr holes.
Important!
Do not grind bonding surfaces down or off.
Installation of side wall holder:

Clean all bonding surfaces with cleaning agent R1.
Apply adhesive to bonding surfaces.
Install new part and rivet with blind rivets.
Release welded connection in area (1) and remove holder (2).

Fit in new part.
In area of adhesive surface (1), drill a 4.2 mm dia. bore hole (2) for blind
rivet N3.
Important!

Apply adhesive to bonding surface.
Install new part and rivet with blind rivet.
41 34 041 Replacing tail panel (E46)

refer to 41Â 00.
Tail panel

Rear bumper
Impact absorbers
Trunk trim panels
Spare wheel
Left and right tail lights
Cable harness (partially)
Lock base
Vent flaps
Battery, if necessary
Expose and open connection points between

lamp console
side wall
water drain.
Expose mating surface, tail panel/side wall.
Expose mating surface, tail panel/luggage compartment floor.
Cut out tail panel roughly.
Clean connection points.

Remove scrap metal. Straighten and grind connection points.
Coat connection points with zinc dust paint.
Clean mating surfaces on tail panel spare part and coat with zinc dust
paint.
Install tail panel, fit with rear lid and fix in position.
Weld tail panel.
Weld tail panel to mating surface, side wall, from luggage compartment.
Weld tail panel to mating surface, water drain, from luggage compartment.
Braze tail panel and grind down at joints of:

water drain (1)
wheel arch extension (2)
side wall (3)
Seal connection points.

.

(1) A-pillar,
refer to 41 00 ...
refer to 41 00 ...
refer to 41 00 ...
refer to 41 00 ...
refer to 41 00 ...
refer to 41 00 ...

refer to 41 00 ...
(8) Entrance, rear,
refer to 41 00 ...
refer to 41 00 ...
B-pillar, inner,
refer to 41 00 ...
refer to 41 00 ...
refer to 41 00 ...

Caution!
shaped part!
Caution!
Note:

Further work,
side member
Caution!
spray can!
Use by date on can.
of BMW AG.
Substrate must be
clean and free from
dust,
grease,
Note:
of 1 hour.
side member

Further scopes,
paint etc.).
Caution!
relative humidity.
Note:
Caution!
Caution!
Parts Service
.
to engage.

necessary.

Remove shaped part.
- 100 grain).

Locate shaped part.



Caution!

41 35 000 Removing and installing or replacing left or right front side panel
Following parts must be removed and if necessary replaced:

Inner wheel arch trim,
Front turn indicator light, completely,
Side turn indicator light,
Rubbing strip on side wall
Replacement:
Also apply sprayable sealing compound on inside of side panel in
area (1).
Material: Terostat 9320 (sourcing reference: BMW Parts Service).
In wheel arch, release retaining screws of side wall at front on cover of

side member (1) and on A-pillar at bottom (2).
In wheel arch, release screw in side wall at front on side wall bracket.
Important!
Do not damage door edge when opening screw; if necessary,
protect door edge by attaching adhesive tape.
Open door.
Release retaining screw on A-pillar at top.
Door at front shown removed for purposes of clarity.

This is not necessary for carrying out this task!
Position of retaining screw with door removed.
Feed out corner (1) of cowl panel cover from side wall at front (2).
Installation:
Corner (1) of cowl panel cover is located behind side wall at front
(2).
Gently lift cowl panel cover upwards.
While raised, grip cowl panel cover firmaly and release retaining screw on
side wall at front.
Important!
Do not damage body parts adjoining front side wall when removing
side wall!
Protect adjoining body parts e.g. by attaching adhesive tape.
Unscrew upper mounting bolts.

Take off side panel.
Installation:
Fit in side panel and make sure of uniform spacing to door and
engine hood.
Refer to 41 00 ... Gap dimensions of doors/hood and luggage
compartment lid
Refer to 41 00 ... Window and door seams
41 33 040 Replacing front left or right side wall holder
Note:
Side wall removed.
Transfer the systematic diagram onto the respective holder version.
Procedure Observe repair stage 2!
Following new body parts are required (refer to Electronic Parts

Catalogue):
Following consumables are required:
Material Quantity
Adhesive K5a 1
Blind rivets N3 2
Cleaning agent R1 1
Release welded connections in areas (1) and remove holder (2).

Adjust new part in conjunction with side panel in front to fit.
In area of bonding surfaces (1), set 2 4.2 mm dia. bore holes (2) for blind
rivetsN3.
Important!

Apply adhesive to bonding surfaces.
Install new part and rivet with blind rivets.
Release welded connection in area (1) and remove holder (2).

Fit in new part.
In area of adhesive surface (1), drill a 4.2 mm dia. bore hole (2) for blind
rivet N3.
Important!

Apply adhesive to bonding surface.
Install new part and rivet with blind rivet.

number 41 11 400).




primer.
Plug-weld area (1).

Plug-weld area (1).
Plug-weld area (1).

Plug-weld area (1).

41 35 101 Replacing rear left side panel (partial replacement, C-pillar)(E46
saloon/sedan)

refer to 41 00 ...
Rear side panel

Rear bumper
All trunk trim panels
Rear wheel
Luggage compartment lid
Rear door
Tail light
Rear seat cushion and backrest
Hatrack
Roof liner
Rear window
Fuel tank
Rear wire harness (partially)
Determine location and mark cutting line on C-pillar.

Dimension (A) = 110 mm from roof edge.
Determine C-pillar separating point in door opening and mark out.
Measurement (A) = 235 mm from square aperture for retaining clip of trim
strip.
Define separating point in cover for side member and mark out.
Measurement (A) = 50 mm from bore for entrance strip (1) with dia. 5.5
mm.
Measurement (B) = 165 mm from bore for panel for cover on side
member (2) with dia. 9.2 mm.
Cut separating points.
Expose rear window frame and water drain mating surface and drill out
welding spots.
Drill out welding spots for reinforcement plate in cover for side member.
Expose connection points between
wheel housing extension
door opening and
wheel arch
and drill out welding spots.
Expose mating surface on floor plate and drill out welding spots.
Expose and open mating surface of

lamp console
side wall
water drain.
Open side wall/tail panel mating surface from luggage compartment.

Open water drain mating surface from luggage compartment.
Caution!
Fire hazard!
Remove rear side panel.

Location of foam parts,
Note:
In the area of the foam, heat up the side panel and separate it from
the foam.
Remove scrap metal. Clean and straighten mating surfaces.
Cut rear side wall spare part.

Measurement (A) = 235 mm from square aperture for retaining clip of trim
strip.
Measurement (A) = 140 mm from bore for entrance strip (1) with dia. 5.5
mm.
Measurement (B) = 140 mm from bore for panel for cover on side
member (2) with dia. 9.2 mm.
Make and fit reinforcement plate for C-pillar separating point from
remaining metal sheet.
Drill holes in C-pillar for plug welding of the reinforcement plate.
Make and fit reinforcement plate for cover separating point for side
member from remaining metal sheet.
Reinforcement plate width = approx. 60 mm.
Drill holes for plug welding reinforcement plate for cover separating point
for side member.
Coat reinforcement plate and mating surfaces on C-pillar with zinc dust
paint.
Slide reinforcement plate into C-pillar approx. 20 mm deep and weld.
Coat reinforcement plate and mating surfaces on cover for side member
with zinc dust paint.
Insert reinforcement plate approx. 30 mm into cover for side member and
weld up.
Fit rear side wall, mark out holes for plug welding reinforcement plate at
C-pillar connection.
Mark out holes for plug welding reinforcement plate in cover for side
member.
Remove rear side wall spare part.
Drill holes for plug welding reinforcement plate at C-pillar connection.

Drill holes for plug welding reinforcement plate in cover for side member.
Clean mating surfaces and coat with zinc dust paint.
Install shaped parts for cavity bulkhead.

cover for side member
Fit rear side wall and secure in position.
At C-pillar connection, set spots close enough together to create an

enclosed seam.
At connection for cover for side member, set spots close enough
together to create an enclosed seam.
Spot weld rear window frame connection.

Mark water drain connection with dots, set brazed seam.
Set brazed seam on spare part in water drain.

wheel housing extension
door opening and
wheel arch
extension.
Weld mating surface on floor plate.

lamp console
side wall
water drain.
extension.
Weld side wall/tail panel mating surface from luggage compartment.
Weld water drain mating surface from luggage compartment.
Grind down all connection points.

Coat C-pillar mating surface and cover for side member with tin and grind.
Re-expose bores that were sealed with reinforcement plates.
Cringe edge of wheel arch in indicated area (1).
Seal connection points.
41 51 004 Adjusting left or right front door
Note:
Doors are fitted and bolted to an unfinished body shell.
Moving the hinges later on makes unpainted surfaces visible. These
surfaces must be touched up with paint in the body color.
Note:
These adjusting instructions generally apply to all body variations
such as Saloon/Sedan, Coupé, Compact, Touring,
Cabrio/Convertible.
On 4-door models, it is important to align the rear doors first.
The reason for this is that the rear doors must be aligned to the
welded rear side walls.
The front doors must then be aligned to the rear doors.
The bolted front side walls can then be adapted if necessary to the
front doors.
On 2-door models, the doors are aligned to the welded rear side walls.
doors.
The illustrations therefore do not always correspond to the type of

vehicle selected in the TIS.
The illustrations are therefore to be viewed as basic illustrations which
are to be carried over to the relevant vehicle type.
Caution!
Slight corrections by straightening are permitted if the existing
adjustment options are insufficient.
Extensive straightening would lead to the doors becoming "soft"
and cause them to lose their tension on a long term basis. At high
road speed and with strong side wind, the door frame could then lift
off of the hose seal.
Note:
Keep to the sequence of procedures for correct alignment of doors.
Before installation, assemble doors with window lifter and glass.
Door settling behavior depends on weight!
Release striker.
Gap dimensions,
refer to 41 00 ... Gap dimensions of doors/hood and luggage
compartment lid
refer to 41 00 ... Window and door seams E46 4-door
Always fit first rear door and then front door,
refer to 41 52 004.
Check previous settings again and repeat work steps if necessary.
Note:
When installing a new door, in order to avoid damage to paintwork,
make sure there is a sufficient gap between door and body.
If necessary, attach fabric tape to points of contact on body.
When installing a new front door, install shims (1) between door and hinge.
Measurements of shims (1) for presetting:
Hinge top/bottom 0.5 mm
Adjust to specified distance by installing spacers in appropriate quantity and/or thickness.
Hand-tighten nuts on door hinges, top and bottom.
Detach cover (1) from closing bar on B-pillar.
Release screws (1) and (2) on B-pillar. Note:

After slackening, the closing bar should be positioned approx. 90° to
the door frame inside edge (3) and should be able to be moved
easily.
Lower front door window.

Slacken nuts on door hinges, top and bottom.
Adjust gap (A) uniformly,
refer to Windows and door seams 41 00 ...
Adjust gap and plane displacement (B) uniformly,

refer to Gap measurements, doors/hood and rear lid 41 00 ...
Check that front door is flush with rear door in terms of height and correct
if necessary.
Correcting height:
Release nuts on hinges (1) and (2) and turn/move door.
Tighten nuts.
Tightening Torque,
Note:
Gap must continue to run uniformly between door and sill. If
necessary, repeat previous work steps.
Check door protrusion, bottom,

If you need to correct, release nuts on hinge (2) and correct deviations
by number and/or thickness of shims on hinge (2).
Tighten nuts.
Tightening torque,
Check door protrusion (2), rear,

Note:
Door height (1): flush
When the door is closed, the closing bar must not make contact or
slip in the lock.
If you need to correct, move closing bar inwards or outwards. Tighten

down screws on closing bar.
Tightening torque,
Attach cover above closing bar on B-pillar.
41 52 004 Adjusting left or right rear door
Note:
Note:
Cabrio/Convertible.
front doors.
doors.

Caution!
Note:
Release striker.
Gap dimensions,
compartment lid
Always first adjust alignment of the rear door and then the front door.
Adjust front doors to fit,
refer to 41 51 004
Note:
When installing a new rear door, install shims (1) between door and hinge.
Detach cover (1) from closing bar on C-pillar.
Release screws (1) and (2) on C-pillar. Note:

easily.
Lower rear door window.


Check that rear door is flush with body in terms of height and correct if
necessary.
Correcting height:
Loosen nuts on hinge (1) and turn door.
Tighten nuts.
Tightening Torque,
Note:
In case of considerable deviation, correct thickness of shim on
hinge (2).

If you need to correct, slacken nuts on hinge (2) and move door, bottom,
out/in.
Tighten nuts.
Tightening torque,
Check door protrusion, rear,

Note:
Door height: flush
slip in the lock.

Tightening torque,
Attach cover above closing bar on C-pillar.
Then align front door,
refer to 41 51 004.
41 51 ... Notes on replacing the door
Important!
For production reasons the side impact beam is only screwed
loosely.
Tighten screws of side impact beam.
Remount all components on the new door.

If necessary, replace damaged components.
The procedure is described in the repair instructions of the components.
41 52 004 Adjusting left or right rear door
Note:
Note:
Cabrio/Convertible.
front doors.
doors.

Caution!
Note:
Release striker.
Gap dimensions,
compartment lid
Always first adjust alignment of the rear door and then the front door.
Adjust front doors to fit,
refer to 41 51 004
Note:
When installing a new rear door, install shims (1) between door and hinge.
Detach cover (1) from closing bar on C-pillar.
Release screws (1) and (2) on C-pillar. Note:

easily.
Lower rear door window.


Check that rear door is flush with body in terms of height and correct if
necessary.
Correcting height:
Loosen nuts on hinge (1) and turn door.
Tighten nuts.
Tightening Torque,
Note:
In case of considerable deviation, correct thickness of shim on
hinge (2).

If you need to correct, slacken nuts on hinge (2) and move door, bottom,
out/in.
Tighten nuts.
Tightening torque,
Check door protrusion, rear,

Note:
Door height: flush
slip in the lock.

Tightening torque,
Attach cover above closing bar on C-pillar.
Then align front door,
refer to 41 51 004.
41 51 ... Notes on replacing the door
Important!
For production reasons the side impact beam is only screwed
loosely.
Tighten screws of side impact beam.
Remount all components on the new door.

If necessary, replace damaged components.
The procedure is described in the repair instructions of the components.
41 61 014 Aligning hood lid
Note:
Engine hood was fitted and bolted in an unfinished body shell.
Unpainted surfaces become visible after subsequent movement.
These surfaces must be touched up with paint in the body color.
Note:
The Bowden cable which connects both hood lid locks must be
completely seated in the guide in the lock on the left and right.
If this is not the case, the Bowden cable will slip in the guide in the
lock after the release lever is pulled and the locks will not open.
Preliminary work:
Unscrew detent buffers from left and right sides of hood lid.
Move stop disk of hood lid kidney

to position ”0”.
”0” points in direction of travel.
Check initial adjustment of left and right lockpins and adjust if necessary.
Check stop screw of hood lid hinge on left and right.
The plastic head of the stop screw must not be damaged or missing;
replace hood lid hinge if necessary.
Fitting in hood lid:

a ) Gap measurements to side walls
Release screws (1) and (2) of hinge on left and right until hinge can be
moved.
Note:
If the adjusting range is not sufficient, loosen hood lid mounting
bolts on body and adjust hinge on body.
Release screws of hood lock upper section on left and right until hood
lock upper section can be moved.
Release screws of retaining hook on left and right until retaining hook can
be moved.
Close hood lid slowly.
Align hood lid to side panels at front and side.
Align hood lid against front side panels.

The hood lid should close flush with the front side panels beside the
headlights.
Tolerance - 1 mm, i.e. the hood lid must be set 1 mm back from the side
panels.
Align hood lid against front side panels.

The hood lid beside the windshield should seal flush with the side panels
at the front.
1 = Front lid
2 = Side panel, front
This is a result of adjustment of hood lid beside headlights.
Adjustment of hood lid next to headlights must always be within specified

tolerance range.
Raise hood lid.

Tighten down released screws on hood lid again.
b) Height to side walls, front
Locks and retaining hooks must snap correctly into place.
Hood lid must be at same height as front side walls.
Unscrew nut (1) and turn lockpin (2) to adjust height of the engine hood.
Close hood lid and check adjustment.

Adjust hood lid to same height on both side walls.
Raise hood lid.

Tighten down lock nut (1) again.
b) Height to side walls, rear
Release screws of hinge on left and right until hinge can be vertically
adjusted.

Align height of hood lid to side walls at front.
Point (1) = measurement (A) = 100 mm.
Height of hood lid to side wall: - 0.8 ± 0.5 mm,
i.e., hood lid is 0.8 mm lower than side wall.
Hood lid may deviate from specification by 0.5 mm higher or 0.5 lower.
Align height of hood lid to side walls at front.

Point (2) = measurement (B) = 150 mm.
Height of hood lid to side wall: - 0.3+0,.3 -0.8 mm,
i.e. hood lid is 0.3 mm lower than side wall.
Hood lid may deviate from specification by 0.3 mm higher or 0.8 lower.
There is a continuous transition of the height of the hood lid to the side
wall within the specified measurements between (1) and (2).
Raise hood lid.

Tighten down released screws on hinges again.
Lower hood lid several times so that the locks can be centered.Caution!
Do not let the hood lid lock.
Tighten down screws of hood lock upper section on left and right.
Pull retaining hook as far as possible in direction of travel.
Position lever of retaining hook in center of gap in kidney.

Check retaining hook for ease of movement; correct position if
necessary.
Close hood lid slowly and make sure retaining hook does not touch any
point and that it snaps correctly into place.
Retaining hook is thus centered.
Raise hood lid.
Tighten down screws of retaining hook.
Caution!
Always check that the retaining hook is working properly!
Adjustment of stop screw of hood lid hinge:
Stop screw (1) set to measurement (A).
Measurement (A) = 9.5 mm.
Place a strip of paper (normal writing paper) (1) between stop screw (2)
and stop on hood lid hinge.
Close hood lid.

While doing so, make sure paper strip remains between stop screw and
stop on hood lid hinge.
The stop screw is correctly adjusted when the paper strip (1) can be
pulled out ”with suction”.
This adjustment is made by turning the stop screw.

If the paper strip can be pulled out ”with suction”, unscrew the stop screw
(1) by measurement (B).
Measurement (B) = 1.0 mm, corresponding to 1.0 turns.
Adjustment of headlights to hood lid:

Check gap measurements of hood lid to kidney, headlights and turn
signal indicators and correct if necessary,
refer to 41 00 ...
Release headlights at mounting points and adjust to prescribed gap

measurement to hood lid.
Procedure, refer to
Removing and installing/replacing and adjusting complete left headlight,
63 12 001
After adjusting gap measurement, visually inspect gap to ensure it is

uniform.
Procedure:
Position yourself in central position approx. 2 - 3 meters in front of car.
The now visible light gap must run between hood lid and headlight at the
same width and parallel to the hood lid.
Adjust gap measurement if necessary.
41 62 014 Adjusting trunk lid to fit
Note:
Engine hood was fitted and bolted in an unfinished body shell.
Unpainted surfaces become visible after subsequent movement.
These surfaces must be touched up with paint in the body color.
The rear lid is adjusted to fit with built-in gas pressure dampers and a
built-in rear lid seal.
If turning adjustment screws or subsequent machining of adjustment
screws exposes surfaces which do not match the car color, touch up
these surfaces in the appropriate color.
Protect bright surfaces against rust.
Preliminary work:
If necessary, press ejectors into detent buffers and turn slightly to left in
this position with a Phillips screwdriver.
This locks the ejectors in the detent buffers.
Unscrew detent buffers from left and right sides of trunk lid.
Check fulcrum pads on lower section of trunk lid lock for damage and
Remove protective caps from trim panel at rear.
Loosen screws on lower section of trunk lid lock until it can just be
moved, enabling it to center itself.
The lower section of the trunk lid lock must not scrape against the upper
section.
Check stop screw of rear lid:
Stop screw with round plastic head:

If a stop screw with a round plastic head is fitted, remove this plastic head
(otherwise there may be grating noises).
Cut or grind off round plastic head, taking care not to damage adjoining
body parts.
If necessary, remove stop screw and then remove round plastic head.
It is not possible to fit a protective cap on a screw with a round head!
The stop screw thus has a flat head, enabling the protective cap to be
fitted.
Use the adjustment instructions for the stop screw with protective cap.
Adjustment instructions for stop screw with protective cap:

If a stop screw (2) with protective cap (1) is fitted, the following
adjustment instructions apply:
Stop screw with a flat head must be fitted.

Screw in stop screw (1) to measurement (A).
Adjusting rear lid to fit at sides:

Unfasten screws (1 and 2) on left and right sides until trunk lid is still just
able to move.Note:
If the adjusting range is not sufficient, release rear lid hinge
mounting bolts on body and adjust hinge on body.
Caution!
Before closing the trunk lid and when closing the trunk lid, ensure
that the body and/or trunk lid are not damaged.
Close trunk lid.
Adjust gap dimensions and position of trunk lid relative to the other
fittings on the body,
refer to 41 00 ...
Tighten left and right screws (1 and 2).
Adjust lower section of trunk lid lock:

(Screws of rear lid lock lower section released until adjustment is
possible)
Close trunk lid, holding down the lock button to prevent the trunk lid lock
from engaging.
This enables lower section of trunk lid lock to adjust itself correctly.
Adjust gap measurements and position of rear lid (height) relative to
other fittings on body,
refer to 41 00 ...
Tighten screws on lower section of trunk lid lock.
Check adjustment of trunk lid and trunk lid lock, repeating adjustment if
necessary.
Screw in detent buffer until left and right sides of trunk lid locate against
detent buffers when closed.Caution!
Trunk lid must not protrude above side panels otherwise height
adjustment can be distorted!
Gently twist ejector in detent buffers to right with Phillips screwdriver. This
unlocks the detent buffers, enabling ejector to emerge.
Adjustment of stop screw of rear lid hinge:

Stop screw (1) set to measurement (A).
Place a strip of paper (normal writing paper) (1) between stop screw (2)
and stop on rear lid hinge.
Close trunk lid.
While doing so, make sure paper strip remains between stop screw and
stop on rear lid hinge.
The stop screw is correctly adjusted when the paper strip (1) can be
pulled out ”with suction”.
This adjustment is made by turning the stop screw.
If the paper strip can be pulled out ”with suction”, screw in the stop screw
(1) by measurement (B).
Measurement (B) = 2.5 mm, corresponding to 2.5 turns.
The material thickness of the protective cap is compensated for when
the stop screw (1) is screwed in.
Fit protective cap (1) on stop screw.

Check that rear lid is in correct position; correct setting if necessary.
Excessive force should not be needed to close the rear lid.
equipment)
Warning!
Important!
direct sunlight.
Important!
Important!
fumes directly.
agent/paint.
cream.
Important!
First Aid:
Recycling:
are being used.


is reached.

cleaner R1.

51 00 ... Notes on component bonding with adhesive tape
Unless specified otherwise in vehicle-specific or component-specific instructions, the following notes apply.
Follow repair notes for bonded gaskets for rubber seals.
1. General notes
Bonding at room and object temperature of >+18 °C.
Newly painted parts may only be bonded after a drying time of at least 24 hours.
Optimal bonding/attachment to the background surface is achieved after approx. 48 hours.
Components must not be exposed to mechanical strain beforehand (car wash, strength test, etc.).
Do not touch bonding area.
It is not the length of time that pressure is applied but rather the force of pressure applied that is
crucial.
Detaching the adhesive tape after pressing destroys the adhesive layer.
2. Auxiliary materials and tools

Cleaning agent R1 or cleaning agent R2
Sika Activator 205
Fluff-free cleaning cloths
Pressure roller
3. Preparations
Remove all adhesive residue or clean new part thoroughly
Clean the areas to be bonded immediately before bonding to remove silicone and grease residues.
Treat adhesive strips on glass or painted surfaces with Sika activator 205.
Note:
Sika activator 205 apply extremely thinly. It must not be coated beyond the bonding surface.
Note: air drying time: ≥ 1 minute
4. Bonding
4.1 Components without preassembled adhesive tape
Pull off liner* from adhesive tape
Position adhesive tape on component and stick on
Press down adhesive tape over entire adhesive area
Continue with Point 4.2
* Liner is the protective film on the adhesive tape.
4.2 Components with pre-fitted adhesive tape

Pull off liner* from adhesive side (if adhesive area is large, do not pull off liner completely)
Align component in correct position on vehicle
Press down component over entire adhesive area
Minimum contact pressure ≥ 15 N/cm² (firm thumb pressure reaches approx. 35 N/cm².)
* Liner is the protective film on the adhesive tape.

51 00 ... Notes on installing rubber window seals
1. Work safety when handling lubricant G14*
Do not eat, drink or smoke in the area of processing/application
Ensure rooms are well ventilated.
Keep away from heat and ignition sources
In event of skin contact: Wash areas of skin affected with soap and water immediately, change work
clothing which has been fouled with lubricant immediately (keep spare work clothing in reserve)
In event of eye contact: Rinse eyes immediately with plenty of water and seek medical advice
Observe safety data sheet (see Aftersales Assistance Portal (ASAP) ‐ Service/Technology ‐ Safety
Data Sheet ‐ 7‐digit part number)
2. General notes
Use only the BMW-approved lubricant for fitting
Application only at room and object temperatures between 18 and 25 °C
Lubricant dries at different rates depending on the quantity, temperature and ventilation and
becomes sticky
Lubricant can only be used for fitting and not for fault elimination (e.g. grating)
Newly painted parts may only be brought into contact with the lubricant after cooling
Optimal bonding to the surface is achieved after approx. 48 h. The rubber window seal must not be
exposed to mechanical strain beforehand. (car wash, strength test, etc.).
Important!
To avoid groaning noises, do not use soapy water (low-surface-tension water with washing-up liquid)
or lubricant containing silicone.
3. Auxiliary materials and tools

Spirit, cleaning cloth, plastic squeegee, needle
LubricantG14*
(* sourcing reference BMW Group Parts Department)
4. Preparations
Heat and remove anti-friction agent residues with a hot air blower or clean new part thoroughly
Immediately prior to fitting, clean the work area with spirit in order to remove silicone and grease
residues
Note:
Air drying time approx. 1 min:
5. Assembly
Apply a thin coating of lubricant to the rear side of the rubber window seal only
Perform fitting within 30 min of applying lubricant
Lubricant dries after fitting and becomes sticky
Designation, repair Designation, Electronic Part number, Electronic Remarks
Lubricants G14 Lubricants G14 83 23 2 360 412 900 ml / Notes
Sika Activator 205 Aktivator 205 83 19 0 030 155 250 ml
Yellow plastic Adhesive tape 83 19 9 410 979 A = 66 mm;

adhesive tape B = 50 mm
Double-sided Adhesive tape 54 11 2 290 978 L = 50 mm/W = 12 mm
adhesive tape
Masking tape Masking tape 81 22 9 400 181 L = 50 mm /
W = 19 mm
W = 30 mm
Eraser disk Scotch Brite eraser disk 51 91 0 402 946 with shaft
Cutting cord Cutting cord 81 43 2 344 272 Notes
Adhesive set K6 Adhesive set K6 83 19 2 317 925
Window glass Window glass adhesive, 83 19 2 289 286
adhesive cold, 1 hour
Profile rubber adhesive 83 19 2 232 322
Set of felt pads Set of felt pads 51 45 2 353 024

2 348 128
72 1 210
Important!
Instrument panel
Entrance area


Installation note:
Note:


Note:
points.
Note:

of collecting tray.
Note:
operations.

Warning!

51 00 ... Safety information for working on vehicles with airbag systems
Warning!
If work is carried out in area of airbag systems, e.g. on:
Door trim panels
Interior trims
Dashboard etc.
the ignition must be turned off in each case.
The ignition must always be off.
The ignition key must be removed from the ignition lock.
This eliminates the danger of injury.
51 00 ... Service position of engine compartment lid

51 0 040
51 2 160
51 2 170
51 2 180
51 2 240
Note: Only the special tool pertaining to the model series can be
selected.
Series Mount
special tool
E46, R50, R52, R53 51 2 160
E53, E60, E61, E63, E64, E71, E72, E81, E82, E88, 51 2 170
E85, E86, E87, E90, E91, E92, E93
E65, E66, E67 51 2 180
E83 51 0 040
E70 51 2 240
Warning!
Danger of injury and damage!
Engine compartment lid must be held by a second person helping.
Note:
The figures below serve as examples for all corresponding vehicles.
The operation is described on the left side; proceed in the same way for
the right side.
Special tool can only be used on housing (1) of gas pressure spring
(thick part).Note:
gas pressure spring can also be installed the other way round (housing
on engine compartment lid).
Special tool can be used in both directions.
Loosen housing (2) of gas pressure spring , left/right.
Slide special tool (1) over housing (2) of gas pressure spring.
Clip ball socket of special tool onto ball stud.
Proceed in same way on other side.
51 11 ... Checking shock absorber (impact absorber) for front bumper

Remove shock absorber (impact absorber) at front.
Note:
The impact absorber shown in the illustration is for viewing purposes only
and may differ from the removed impact absorber.
Check dimension (A).

Dimension (A) is measured from center of pin boss up to mounting face
for body (without gasket).
Replace impact absorber (1) if measurement drops below dimension (A).
51 11 ... Installing/replacing license plate (without base)
Initial fitting:
Place drilling hole template (1) on bumper (2).
Note:
Hole diameter = 2.5 mm (see template).
Drill holes according to license plate.

Remove template (1).
Secure license plate with screws provided.
Fit protective caps.
Repairing thread:
Drill out defective hole in bumper (2) to 9.5 mm diameter.
Insert blind rivet nut (1)*.
Secure license plate (3) with license plate screw (4)*.
Note:
* Sourcing reference: BMW Parts Service
51 11 000 Removing and installing complete front bumper (from 10/01)

00 9 321
Note: Repair sequence only applicable to E46 cars (except

compact) from model redesign (10/01).
Release screws (1) on left/right.

Lever out clips (2).
Release impact absorber screws (1).Installation:

Lever out wheel arch liner (1) on left/right with fishbone 00 9 321 , pulling
bumper (2) forwards slightly in so doing.
Firmly pull off bumper on both sides towards front. In so doing, grip
primarily edge of wheel arch (1) (do not pull at sides).Caution!
Do not pull bumper too far; there is a risk of damage to the electrical
fittings (connecting cable, air horn, fog lamps).
Installation:
Retaining lugs (1) must not be damaged.
Disconnect plug connections (1) of air horn on left/right.
Version with fog lamps:

Also disconnect plug connections (2) of fog lamps on left/right.
Remove bumper (3) towards front.
Installation:
Height of bumper is adjusted by turning hexagon socket head screw
(1) on impact absorber (2).
Installation:
After sliding in bumper, clip panel into place sideways if necessary (by
pressing gently on edge of wheel arch to center of car).
In so doing, pay attention to alignment to turn signal lamp housing.
Carry out same work in event of slight parking bumps.
Installation:
Adjust all-round gap (A) between bumper and body cutout as uniformly
as possible.
1. Bumper
2. Body
3. Seal
51 11 000 Removing and installing complete front bumper (up to 9/01)
Unfasten left/right screws (1).
Release screw (1) on left/right and lift out wheel arch finishers (2) on side.
Release screws (1) on impact absorber on left/right.Installation:

Tightening Torque,
Pull out bumper a little

and disconnect plug connection (1) of air horn on left/right.
Disconnect plug connection (2) of fog lamps on left/right.
Remove bumper (3).
Installation:
Ideal adjustment:
Gap (A) should be uniform along the full length between bumper and
aperture in body.
Dimension (A) = 5 ± 1 mm
51 11 180 Removing and installing/replacing trim grill for bumper trim (up to
9/01)

Remove complete front bumper.
Unhook catches (1) on grill (2) on left/right and press forward a little.
Unhook grill (1) from catch (2)

and remove on left/right from bumper (3).
Unhook catches (1) and remove grill (2).

51 11 794 Replacing a shock absorber (impact absorber) for front bumper

Remove bumper.

none
Drill out rivets (1).

Release screws (2) and
detach impact absorber (3).
Installation:
Installation:
Installation:
Fit dust cap (1) on impact absorber (2).
51 11 158 Replacing baseplate for license plate
Unscrew and remove license plate.

Remove both rubbing strips,
refer to 51 11 170.
Release screws (1) and remove base (2) for license plate.
51 11 170 Replacing body molding for left or right bumper
Unclip rubbing strip (1) with special tool 00 9 321 (folding leg)
first at front, then at side,
pull out at side from bumper (2)
and remove.
Installation:
Push rubbing strip (2) at side into bumper.
Slide guide (1) of rubbing strip (2)
into support (3) of base (4)
and clip in rest.
51 11 701 Replacing bracket for front left or right bumper (saloon/sedan and
touring from 10/01)

Remove bumper.
Loosen screws (1).

Pull bracket forwards out of T-guide (2).
Installation:
Feed inner bracket (1) into T-guide (2).
Loosen screws (1).

Detach bracket to middle from metal fold (gently pull downwards if
necessary).
Installation:
1. Level for placing on metal fold
2. Level for subsequent clipping in of bumper
51 11 701 Replacing bracket for front left or right bumper (saloon/sedan and
touring up to 9/01)

Remove front bumper.
If necessary, mark position of bracket (2) on body.

Unfasten screws (1) and remove bracket (2).
Ideal adjustment:
Gap (A) should be uniform along the full length between bumper and
aperture in body.
Dimension (A) = 5 Â± 1 mm
51 11 001 Replacing front bumper (from 10/01)

Remove holder for license plate.
Remove rubbing strips.
Remove complete front bumper.
If necessary, remove front fog lamps.
Release expansion rivets on left/right.
Release expansion rivets on left/right.
Release nuts on left/right.

Remove bumper bracket.
Replacement of center bumper section (bracket) only:
Release nuts (1) on left/right and remove air horn (2) from bumper
bracket (3).
Replacement of center bumper section (bracket) only:

If necessary, release split pins (1) on left/right and remove mounting
sleeve (2) from center bumper section (3).
Replacement of bumper trim only:

Remove trim grill for bumper trim.
Lever out cover (1) for towing lug and feed retaining strap (2) out of
bumper.
Detach piping (3) towards rear.
51 11 001 Replacing front bumper (up to 9/01)

Remove complete front bumper,
refer to 51 11 000.
Replace base for license plate,
refer to 51 11 158.
If necessary, remove both fog lamp inserts (complete),
refer to 63 17 000.
Replacing center section of front bumper (support beam):

Release left/right expansion rivets (1).
Release expansion rivets (1) and remove bumper support (2) towards
rear.
Replacement only (bumper center section):

If necessary, release nuts (1) on left/right and remove fanfare (2) from
bumper center section (3).
Replacement only (bumper center section):
If necessary, release split pins (1) on left/right and remove installation
sleeve (2) from bumper center section (3).
Note:
The work for ”Replacing front bumper center section (carrier)” ends
here.
Replacing front bumper (bumper trim):

Remove grill for bumper trim,
refer to 51 11 180.
Remove metal nuts (1) on left/right.
If necessary, detach retainer (2) for fog lamp.
Detach edge guard (1) from bumper (2).
Lever out cover (1) for towing eyelet and detach retaining strap from
bumper (2).
51 11 157 Replacing front bumper trim

Replace front bumper.
51 11 011 Replacing front center section (carrier) of bumper

Replace front bumper.
51 12 ... Checking shock (impact) absorber for rear bumper
Remove a shock absorber for rear bumper.
Note:
The impact absorber shown in the illustration is for viewing purposes only
and may differ from the removed impact absorber.
Measurement (A) is measured from the center of the pin eye to the
contract surface to the body without the seal.
Impact absorber (1) must be replaced
if measurement (A) drops below specified value.
Check measurement (A).
51 12 000 Completely removing and installing (from 09.01) bumper
Release screws (1).

Release screws (2) from impact absorber.
Important!
In the following operation, bridge (1) on latch must not be damaged.
Carefully press down retaining lug (1).

Detach bumper.
Installation:
Carefully press retaining lug (1) upward.
Lift out wheel arch trim (1).

Pull bumper (2) straight back.
If necessary, disconnect plug connections to ultrasonic sensors.
Installation:
Set gap (X) between bumper and body aperture equal all around.
Gap dimension (X) = 2 +0.8/-0.5 mm
Designation, repair Designation, Electronic Part number, Electronic Remarks
Lubricants G14 Lubricants G14 83 23 2 360 412 900 ml / Notes
Sika Activator 205 Aktivator 205 83 19 0 030 155 250 ml
Yellow plastic Adhesive tape 83 19 9 410 979 A = 66 mm;

adhesive tape B = 50 mm
Double-sided Adhesive tape 54 11 2 290 978 L = 50 mm/W = 12 mm
adhesive tape
W = 19 mm
W = 30 mm
Eraser disk Scotch Brite eraser disk 51 91 0 402 946 with shaft
Cutting cord Cutting cord 81 43 2 344 272 Notes
Adhesive set K6 Adhesive set K6 83 19 2 317 925
Window glass Window glass adhesive, 83 19 2 289 286
adhesive cold, 1 hour
Profile rubber adhesive 83 19 2 232 322
Set of felt pads Set of felt pads 51 45 2 353 024
51 12 000 Removing and installing complete rear bumper

00 2 150
Note:
Version with trailer tow hitch:
Remove cover.
All models:
Remove cover on rear bumper panel.
Saloon and Touring:

Bond fabric adhesive tape (1) below screw on bumper (risk of damage).
Connect special tool 00 2 150 to reversible ratchet and release screw on
left/right.
Note:
Only Saloon with M Aerodynamics package:
The screw can be removed downwards.
Installation note:
Saloon and Touring:

Pull bumper (1) to the rear/bottom and remove screw (2) to the
rear/bottom.
Important!
Risk of damage!
Coupé and Convertible:

Connect special tool 00 2 150 to reversible ratchet and release screw on
left/right.
Installation note:
Coupé and Convertible:
Pull bumper (1) to the rear/bottom and remove screw (2) to the
front/bottom.
Important!
Risk of damage!
Version with Park Distance Control (PDC):

Unclip left cable clip (1) left downwards.
Version after 12/98:

Release nut (1) on left/right.
Pull off holder (2) from the bumper (3).
Installation note:
Release expanding rivet (1) on left/right.

Pry out wheel arch trim (2) on left/right and pull bumper (3) slightly
towards rear.
All except for Convertible with TV:
Pull off bumper (3) towards rear.
Only Convertible with TV:
Remove storage compartment on left in luggage compartment.
Only Convertible with TV:

Pull out connector with grommet (1) towards rear.
Release nut (2) on left/right.
Pull off bumper (3) towards rear.
51 12 080 Removing and installing/replacing finisher strip on bumper trim
Remove detent lugs (1) on one side from below, then unclip rest of
finisher strip (2).
Version without Park Distance Control (PDC):
Remove finisher strip (2).
Version with Park Distance Control (PDC):

If necessary, disconnect plug connections (1) from ultrasonic
converters (2) and finisher strip (3).
Replacement only:
If necessary, remove retainers (1) and ultrasonic converter (2).
51 12 825 Removing and installing/replacing guide for rear centre bumper
(from 09/01)
Release all screwsÂ (1).

If necessary, detach wiring harness for PDC sensors from guide.
Remove guide.
51 12 011 Replace center section of rear bumper (support beam)
Operation is described in: Replacing rear bumper.

51 12 157 Replace rear bumper trim

Replacing rear bumper,
refer to 51 12 001
51 12 437 Replacing all protective strips for rear bumper

Replace rubbing strip for bumper at rear middle.
51 12 801 Replacing bracket for rear bumper at left or right
(bumper removed)
If necessary, remove complete rear bumper,
refer to 51 12 000.
Installation:
If necessary, mark position of bracket on body.
Release screw (1) on wheel arch.
Release nuts (1) and remove bracket (2).

51 12 801 Replacing bracket for rear bumper at left or right (starting 9/01)
Release screwsÂ (1).

51 12 432 Replacing central body molding on rear bumper

00 9 321

Remove rubbing strip for bumper at rear side left and right.
Unclip and remove molding (1) with special tool 00 9 321 (folding leg).
51 12 435 Replacing left or right side molding for rear bumper

00 9 321
Unclip rubbing strip first at rear then at side with special tool 00 9 321
(fishbone) and remove at an angle towards rear.
Installation:
Insert rubbing strip first at front (1) and then clip into place.
Saloon/sedan, compact: Installation:

Replace rubbing strip if detent lugs (1) are faulty.
touring: Installation:
Replace rubbing strip (2) if detent lugs (1) are faulty.
51 12 742 Replacing one shock absorber for rear bumper
Release expansion rivets (1) and remove tray (2).Installation:

If necessary, remove luggage compartment wheel arch trim on left.
Version with battery in luggage compartment:

Turn rotary clips (1) through 90°.
Feed shelf (2) out of luggage compartment wheel arch trim (3).
Unclip cover (1) on left and right.
Release nuts (1) on inside and remove shock absorber.Installation:

Tightening Torque 51 12 3AZ.
Installation:
Mount seal (2) on shock absorber (1).
Fit protective cap (3) to right shock absorber (1).
Installation:
If necessary, fit a new gasket (1) and a new cover (2) to shock
absorber (3).
Adjusting bumper:
Ideal adjustment:
Distance (A) must be the same all around between the bumper and body
cutout.
Distance (A) = 2+0.8 / -0.5 mm.
51 12 001 Replacing rear bumper
Replacing rear bumper center section (carrier) (51 12 011):

Remove complete rear bumper.
Release expansion rivets (1) and remove bumper center section (2)
(carrier).Note:
Shock absorbers are not on carrier.
Installation:
Make sure nut (1) is properly fitted in carrier (2).
Note:
The work for ”Replacing rear bumper center section (carrier) (51 12 011)”
ends here.
Replacing rear bumper trim (51 12 157) and replacing rear bumper (51
12 001):
Remove protective strip for bumper at rear center.
Unclip cover for towing eye at opening (1) and remove retaining strap (2).
51 13 402 Removing and installing handle strip (on trunk lid)
Version from 10/99:

Remove panel for rear lid in rear area.
Feed out wiring harness (2) in direction of arrow from bracket (1).
Release screws (1) and withdraw handle strip (2) somewhat.

Version from 10/99:
Remove strip handle (2).
Installation:
Check function.
Version up to 10/99:
Disconnect plug connection (1) and remove handle strip (2).
Installation:
Check function.
51 13 280 Removing and installing trim strip on roof frame at left or right
Lever out trim strip (1) with special tool 00 9 321 at rear and unclip the
rest.
If necessary, replace faulty clips (1) or seals (2) on trim strip (3).
Installation:
Slide trim strip (1) at front into seal (2),
clip in at front and rear so it is flush with edge (3)
and then clip in the rest.
51 13 115 Removing and installing/replacing cowl panel cover
Remove both windshield wiper arms,

refer to 61 61 100.
Remove microfilter for interior ventilation,
refer to 64 31 010.
Unclip cover (1) on cowl panel.
Installation:
If necessary, replace faulty clips (1) in cover (2).
Replacement only:
If necessary, remove seal (1) from cover (2) for cowl panel.
51 13 001 Removing and installing/replacing front radiator grill, middle left or
right
Open hood.
Lever out catches (1) on left/right and (2) at bottom.

Front radiator grill (3) is movable.
Feed out front radiator grill (1) from lever (2) and engine hood.
After removal, lever out upper catches (3) and detach inner section from
chrome ring.
Installation:
Retaining lugs (1) and catches (2) on inner section (3) must not be
damaged.
Installation:
Catches (1) and guides (2) on chrome ring (3) must not be
damaged.
Installation:
Assemble chrome ring (1) and inner section (2).
Ensure correct locking.
Installation:
Press on chrome ring to push front radiator grillÂ (1) into engine
hood.
The supports (2) must lock correctly.
51 13 065 Removing and installing / replacing trim cover on left or right
headlight housing (Saloon, Touring)
Build date up to 09/2001:

Version with headlight washer system:
Remove washer jet of headlight cleaning system .
Unclip inner cover.

Press cover down and out from the holders (1) and pull out hooks (2).
Build date after 09/2001:

Remove turn indicator .
Version with headlight washer system:
Remove washer jet of headlight cleaning system .
Press retaining lug (1) and pull out cover (2) in direction of arrow.
Press retaining lug (1) and remove cover (2) in direction of

arrow.Installation:
Ensure adhered seal (3) is seated correctly.
51 13 316 Removing and installing/replacing trim strip on roof gutter at left
or right
Note: Two people are needed to remove and install the trim strip.
Note:
The trim strip (1) is secured with 15 clips (2).
Note:
Make sure body is not damaged in area of A- and C-pillars.
In first operation, only unclip trim strip (1) up to center of C-pillar.
Carefully unclip trim strip (1)

with special tool 00 9 318 (universal wedge)
at top of A-pillar towards front and then towards rear up to center of C-
pillar.
Unlock rear trim strip (1) and remove towards top from last clip (2).
Installation:
To avoid leaks and noises, check all clips (2) for visible damage.
Loose or damaged clips (2), as shown in illustration, must be
replaced as follows:
- Knock through split pin (1) with split pin driver and hammer,
- split pin (1) is allowed to drop into inside of side frame,
- remove clip(s) (2) by hand.
Installation:
Seal (1) on clip (2) must not be missing (leakage).
- Insert clip (2) in bore,
- press in split pin (3) until flush with clip (2), do not knock in (risk of
damage, denting).
Coat area (A) of C-pillar with soapy solution.

Note:
Be sparing with soapy solution on account of contamination and risk
of accident (risk of slipping if spilled etc.).
Attach protective strip (1) at height of breastwork (2).
Caution!
- Carry trim strip in middle only (risk of damage),
- carry out installation with two persons,
- prepositioning of trim strip,
- ensure gutter runs parallel to side frame (risk of breakage).
Installation on clip 15 (last clip):

(A):
Snap trim strip (1) into last clip (2) (audible click).
(B):
Slide trim strip (1)
downwards in direction of breastwork (3)
up to stop of retainer (clip mount in trim strip).
Installation on clips 13 and 14:
Snap trim strip (1) into clips (2) (audible double click).
Pull trim strip (1) in area of clips (2)

with both hands towards rear/bottom as far as it will go.
End of trim strip (1) must not rest on paint of breastwork (3).
Installation on remaining clips:

Position trim strip (1) on remaining clips (2)
from rear (A) to front (B) and clip into place (audible click),
do not knock in (risk of damage, denting).
Visual check:
Correct:
Notch (1) on rubber plug (2) of trim strip (3)
is flush with front side wall (4) (wheel arch).
Incorrect:
Trim strip touches side wall (4).
51 13 286 Replacing bracket for roof luggage rack on left or right

00 9 322

Remove trim strip from roof frame
Remove body sealing compound (1) with special tool 00 9 322 and
unfasten threaded pin (2).
Note:
Threaded pin is designed as Torx from E87 model series.
Installation:
Threaded pin may not be wetted with screw securing adhesive on screw-
in thread (1).
Before installing threaded pin, protect body against corrosion (e.g. apply
zinc dust paint).
Apply body sealing compound (1) (Terostat 9320, sourcing reference:

BMW Parts Service) to threaded pin (2) all round.
After hardening time of body sealing compound (1) (refer to
manufacturer's specifications), paint over body sealing compound (1)
and threaded pin (2) with paint pencil of corresponding car colour.
51 13 403 Replacing handle strip (on trunk lid)
Remove handle strip,

refer to 51 13 402.
When replaced, the button comes in individual parts because the
panel must be painted in the relevant car colour.
Lever out light strip (1) on left/right from opening (2) and remove.
Remove light bulb (3).
Remove seal (1) from handle strip (2).
Note:
During removal, do not damage catches (1) of panel (2).
Carefully lever panel (2) with special tool 00 9 322 (plastic wedge) out of
handle strip (3) and remove.
Installation:
Catches (1) and guides (2) on panel (3) must not be damaged.
Remove remnants of adhesive (1) from handle strip (2).Installation:

Perform function check with trunk lid open.
51 13 282 Replacing trim strip on roof frame at left or right
Removing trim strip on roof frame at left or right,

refer to 51 13 280.
Slide plastic unit (1) in trim strip (2) approx. 20 mm to one side; this
moves the steel pin.
When the plastic unit (1) is at the aperture,

the cover (2) folds open.
Remove cover (1) with steel pin (2) from trim strip (3).
After removing cover (1), remove plastic unit (4) upwards to aperture.
Note:
Steel pin (1) on cover (2)
is secured by retainer (3) of plastic unit (4)
in trim strip.
Slide out retainers (3)
over apertures (1) of trim strip (2).
Remove seals (1) and (3) from trim strip (2).Installation:

New seals (1) and (3) are longer than trim strip (2).
After inserting, form seals (1) and (3) a little by upsetting (push
together).
Cut seals (1) and (3) an ends to trim strip (2).
Glue ends of seals (1) and (3) with Loctite 380 (sourcing reference:
BMW Parts Service).
Installation:
Align retainers (1) of trim strip (2) to brackets (3) on roof.
Installation:
Push steel pin (1) into cover (2) on one side until flush.
Installation:
Insert cover (1) in trim strip (2) and push in steel pin (3) in center.
Installation:
Pay attention to installation position of plastic unit (1).
Clip plastic unit (1) into trim strip (3);
in this case, steel pin (4) must be between retainers (2) of plastic
unit (1).
51 14 ... General notes for labelling with adhesive films
In the event of a repair the adhesive films must be partially or completely replaced. The basic procedure for all
areas of the vehicle is described below.
In addition, vehicle-specific repair instructions are available.
1. Preparation:
Wash and dry vehicle. Rework with compressed air as required in area of joints.
Clean complete component surface with glass cleaner (BMW part number 83 12 0 396 775). Also clean the
inside of the component in areas, in which adhesive films are applied.
Only carry out repair work with clean hands!
Important!
Labels can only be applied to recently painted components after a waiting period of 2 weeks. The paint
hardening is only fully completed after this time.
2. Procedure for applying labels:
All adhesive films in the repair kit are marked with numbers. Prepare the required plastic films prior to start of
repairs.
The templates included in the repair kit assist orientation. A straight line running over the different components
is the top priority.
Pull off the templates positioning of the adhesive films.
Only throw away templates after completion of all repair work, as some templates are used several times.
Templates are always
applied along the light
edge (1). The light
edge is the reflection
of the light source in
radius (see arrow).
Roughly align the adhesive film using a template.

For large adhesive films, pull off the first 20 cm of protective film and fold back the edge.
Align and lightly press down the adhesive film. Use only one finger for this and not the entire hand so that air
pockets are unable to form under the adhesive film.
Pull off the remaining protective film and press down the adhesive film from front to rear and from inside to
outside.
If faults are made in applying the adhesive film, it can be pulled off and repositioned several times. When no
further corrections have to be made, use a squeegee to press down the adhesive film firmly from inside to
outside.
Lay protruding ends of the adhesive film around the component edge and press down firmly.
Carefully pull off
backing film (1) at an
acute angle.
51 14 ... Instructions for attaching number/letter designation combination
Note:
The model designation is attached with adhesive and can not be
reused.
The model designation must be attached at room temperature
>±18 °C.
The model designation must be removed at stove-enameling
temperatures exceeding 80 °C.
Note:
The following work steps are described using the ”316 i” as the example.
Removing:
Coat nylon string or strong yarn with tensides (e.g. washing-up liquid).
Cut through adhesive layer and remove model designation (1) from rear
lid (2).
Remove remainder of adhesive layer with adhesive remover (sourcing
reference: BMW Parts Service).
Assembly:
Number and letter combinations (1) of the model designation are not
connected to each other and are supplied on a carrier film (2).
Important!
Adhesive areas must be dry and free of dust and grease.
Once it has been cleaned, do not touch the adhesive area with bare
hands.
Remove liner (3) (protective strip for adhesive surface).

Firmly press down model designation.
Remove carrier film (2).
51 14 000 Removing and installing/replacing front BMW badge

00 9 325
Important!
Risk of damage!
To avoid damaging the paintwork on the engine hood/bonnet, tape off

edge areas (1) to sides of guide pins.
So as not to subject the BMW badge to excessive deformation, lever
out the badge with special tool 00 9 325 at guide pins (2).
Installation:
The following parts must not be damaged or missing, replace if
necessary:
1 Badge
2 Guide pins
3 Grommets
Adhesive tape (4)
51 14 010 Removing and installing/replacing rear BMW badge
Operation is identical to:

Removing and installing/replacing front BMW badge.
51 14 110 Removing and installing/replacing rear model designation
Important!
The ”Instructions for number/letter combination cementing” serve as
the basis for these repair instructions and must be followed without
fail.
Fitting dimensions for Saloon:
Stick on adhesive tape up to top edge ”A” and mark out measurement ”B”.
Saloon 316 i ... 330 i:
A= 50 mm
B= 25 mm
Saloon 318 d ...330 d:
A= 50 mm
B= 25 mm
Fitting dimensions for Coupé and Convertible:

Stick on adhesive tape up to top edge ”A” and mark out measurement ”B”.
Coupé (all except M3) A = 55 mm B = 15.5 mm

M3 Coupé A = 42.5 mm B = 41 mm
Convertible (except M3, 320 Cd) A = 42.5 mm B = 21 mm
M3 Convertible A = 16.4 mm B = 10.8 mm
320 Cd Convertible A = 56.5 mm B = 19 mm
Fitting dimensions for Touring:
Stick on adhesive tape (1) from edge of rear lid (2) up to top edge measurement ”A” and mark out measurement ”B”.
Observe measurement ”C” when sticking on number/letter combination.
Touring 316 i...330 i:
A= 35 mm
B= 25 mm
C= 1 mm
Touring 318 d...330 d:
A= 35 mm
B= 25 mm
C= 1 mm
Touring 325 xi, 330 xi, 330 xd:
A= 35 mm
B= 25 mm
C= 1 mm
Fitting dimensions for Compact:
Stick on adhesive tape (1) from edge of rear lid (2) up to measurement ”A” and mark out measurement ”B”.
Observe measurement ”C” when sticking on number/letter combination.
Compact 316 ti ... 325 ti:
A= 41 mm
B= 134.5 mm
C= 1 mm
Compact 318 td, 320 td:
A= 41 mm
B= 134.5 mm
C= 1 mm
51 15 330 Removing and installing or replacing body molding on left or right
front door
Unclip rubbing strip (1).
If necessary, lift clips off doors.

Installation:
If necessary, replace faulty rubber grommets (1) and clips (2).
Attach clips to body molding in rubber grommet and align.
Prior to installation, coat rubber grommets (1) with soapy solution
(washing-up liquid).
Clip rubbing strip into door.

51 15 360 Removing and installing rubbing strip on rear door on left or right
Unclip rubbing strip (1).
If necessary, remove clips from rear door.

Installation:
If necessary, replace faulty rubber grommets (1) and clips (2).
Attach clips to body molding in rubber grommet and align.
Prior to installation, coat rubber grommet (1) with soapy solution
Clip rubbing strip into rear door.

51 16 992 Disassembling and assembling lock barrel (lock barrel removed)

If necessary, remove lock barrel
Note:
Lock barrel repair kit *(part number: 9 061 387 valid for:
E30
E31, E32, E34, E36, E38, E39
E46, E52, E53, E60, E61, E63, E64, E65, E66, E67, E84, E85, E86,
E90, E91, E92, E93
* sourcing reference BMW Group Parts Department
Sort supplied clamps (1) by stamped numerical sequence (X) in

ascending order and number (Y).
Insert spring (1) into first lock barrel position (2).Note:

lock barrel version (2) differs from vehicle to vehicle.
Insert clamp (1) with lowest number (X) of first position (Y) in lock
barrel (2) and snap audibly into place.Note:
Number of clamps (1) differs from vehicle to vehicle.
Insert ignition key (1) in lock barrel (3) and check whether retainer (2) is
flush with housing.
(A) OK
(B) not OK
If clamp (2) is not OK, press clamp (2) out of lock barrel (3) with a suitable
tool (1).
Continue with next number (X) higher of first position (Y) until clamp is
OK.
The continue with all the other positions in accordance with the above-
mentioned procedure.
51 16 ... Gluing of mirror base
Material Requirements:
Repair set for gluing of mirror base (Sourcing Reference: BMW Parts Department)
Primer XW 775 (Sourcing Reference: BMW Parts Department)
1. Preparation
1.1 Glue at room temperature and make sure that, in cold weather, the windscreen and base are brought to
room temperature in the workshop long enough to prevent condensation forming on the surface.
1.2 Mark position of the mirror mount on the outside of the windscreen.
Scratch off adhesive residue on windscreen and base with a sharp tool.
1.3 Clean glue area on window and base with clean non-fluffing cloth and alcohol/cetone and allow to dry!
Never use paint thinners!
2. Primer coat
Apply colourless, diluted primer to bonding surface of windscreen with help of cotton buds (Q-Tips or
similar).
Specified air drying time at least 1 minutes, maximum 1 hour
3. Bonding coat
3.1 Mixing adhesive
Cut off sealing tips on containers of glue and hardener using a knife.
Make sure that both openings are equal in size, as otherwise there would be mistakes in mixing.
The sealing cap for subsequent plugging of the double injector is located between both pistons of the
syringe. Break off sealing cap.
The required amount of glue and hardener is removed by applying light pressure on the pistons.
The mixture ratio of adhesive and hardener is 1 : 1 (weight and volume). It is important that the same
volumes of glue and hardener are removed (increase size of openings if necessary).
Both components react chemically with each other. Thorough, intensive and homogenous mixing is a
prerequisite for this reaction and for the quality of gluing.
Consequently both components must be mixed in such a way that there is a uniform, ream-free colour
mixture.
3.2 Application
At 20 ... 25 °C the mix can be processed after approx. 5 ... 10 minutes (pot time).
Apply thin (approx. 0.5 mm), uniform coat of adhesive on base with spatula and press base onto glass in
such a way that adhesive obtains good contact with windscreen across the entire surface area.
Note:
The temperature for the hardening process should not be lower than +18 °C.
3.3 Fixing Bonded Parts
Epoxy resin glue does not have an initial strength property. It is therefore necessary to fix all bonded
parts (adhesive tape or similar). The joining and fixing of bonded parts must be accomplished within the
potlife). Check that the arresting button is located correctly on the mirror base to ensure that the mirror,
when it is attached, is seated straight.
(Long side of mirror base hexagon parallel to upper edge of window).
3.4 Hardening of adhesive
Hardening speed depends on the ambient temperature.
For this reason, the mirror base must be secured with adhesive tape or similar for at least 3 ... 4 hours.
After 12 hours have elapsed, clip mirror into place as soon as possible.
4. Working hygiene
Important!
Glue is dangerous for health when vapours are inhaled or through contact with the skin.
As is the case for all epoxy resins, sensitive persons might be confronted with an allergy through contact
with the skin.
If the product gets on the skin, wash off with soap and water immediately.
If it gets in an eye, rinse the eye thoroughly in water and consult doctor.
Make sure that the room is well ventilated and that protective glove are worn for the application of
adhesive.
51 16 210 Removing and installing / replacing finisher for preselector lever
Note:
Do not wrench knob when removing as this will cause the anti-
wrench element in the knob to be shorn off.

Attach knob to selector lever, align and press on until it snaps
audibly into place.
Installation:
Push rubber gaiter (1) down until grooveÂ (2) is fully exposed.
Installation:
Pull rubber gaiter (2) of trim (1) down and fit onto selector lever (4).
Attach cable plugs (3) and (5) to trim (1) in center console.
Remove trim (1) with rubber gaiter from center console.

Disconnect cable plugs (1) and (2).
51 16 063 Removing and installing / replacing interior rearview mirror (with
remote control)

Removing and installing/replacing interior rearview mirror.
51 16 195 Removing and installing center armrest
Remove storage tray,

refer to 51 16 200.
Slacken screw (1), do not release.

Press down spring (2) and remove cable (3).
Feed out cables (3) and (4) through hole (5) in center armrest.
Unscrew bolts (1).Installation:

Fit screws (1) with space bushings (2).
Push center armrest (1) towards rear until screwÂ (2) is located in
assembly hole and remove armrest (1) towards top.
Installation:
If necessary, replace faulty metal nuts (1) in center armrest (2).
51 16 350 Removing and installing left glove box
Open glovebox.
Release screws (1) and remove glove box (2).
51 16 480 Removing and installing or replacing front grab handle
Lift out and remove trims (1).
Release screws (1) and remove grab handle (2) with carrier (3).
51 16 080 Removing and installing or replacing sun visor and left or right
counter support
Lift out sun visor (1).

Version without interior light package:
Unfasten screws (2) and remove sun visor (1).
Version with interior light package:
Release screws (2) if necessary,
pull out lighting cable a little,
disconnect plug connection and
remove sun visor (1).
Installation:
Perform function check on lighting.
Lift out inserts (1).

Release screws (2) and remove counter support (3).
51 16 360 Removing and installing right glove box
Open glovebox.
Detach pin (1) from retaining strap (2).
Detach pin (1) from shock absorber (2).
Unscrew bolts (1).

Remove bracket (2) and glove box (3).
51 16 200 Removing and installing storage tray
Press roller cover (1) down a little; this pushes the storage tray (2) up a
little.
Take out shelf or ashtray towards top.
Release screws (1) and remove bracket (2) for shelf or ashtray.
Smoker package:
Disconnect plug connection (1) and remove bracket (2).
Release screws (1).Installation:
If necessary, feed out wire for ashtray light.
Remove catches (1) and detach trim (2) towards top.
Installation:
Catches (1) and guides (2) on insert (3) must not be damaged.
Unclip boot.
Version without center armrest:
Feed storage tray out towards rear and remove.
Unclip boot.
Release screws (1).

Raise trim (2) and feed out storage tray (3) towards rear.
Disconnect plug connection for hazard warning lights/central locking.
Version with car phone:
Raise storage tray and disconnect plug connections.
Version without center armrest:
Feed storage tray out towards rear and remove.
Version with center armrest:

Set up center armrest (1).
Feed out storage tray (2) above center armrest (1) and handbrake lever
(3).
51 16 060 Removing and installing/renewing inside mirror (with Japanese
inside mirror with electronic toll function)
Important!
Work may only be carried out at a room/object temperature of
18 ... 28 °C.
If this can not be guaranteed (cold/hot countries), it is necessary to
equalise the temperature of the windscreen, mirror base and inside
mirror (e.g. vehicle left to stand indoors or in the shade for at least
30 minutes).
Version with remote key for central locking system:

If necessary, disconnect negative lead from battery.
Version with compass:

Check compass function if replacing or after disconnecting inside mirror
plug connection or battery.
If necessary, calibrate compass in interior rearview mirror.
E60 Security version:

Rain sensor is not installed, cable connection is tied back in headlining.
Important!
To avoid windscreen breakage:
Screw inside mirror off mirror mount.
Inside mirror must not be pulled or pressed off towards front or rear.
Press on end caps (1) and at same time pull them apart; this releases
clip connection of both caps (1).
Turn inside mirror (1) to right and left and feed out end caps (2).
Installation note:
Latch mechanisms (1) and guides (2) of end caps (3) must not be
damaged, replace if necessary.
Disconnect plugs (1 and 2).

Note:
Pay attention to cable routing for rain sensor.

Important!
Do not pull or press inside mirror off towards front or rear.
Twist mirror base approx. 45° to right until mirror base is released from
mirror mount.
Installation note:
1. Twist mirror foot by approx. 45° and fit to mirror base .
2. Turn mirror base until it engages on mirror mount.
Only in case of replacement with version with remote control for

central locking:
If necessary, initialise all transmitters (ignition keys), refer to Owner's
Handbook.
51 16 ... Removing and installing/replacing carrier in storage tray
Removing insert (compartment) in carrier:

If necessary, open cover (1).
Press insert (2) upwards in center with hand
and simultaneously remove insert (2).
Installation:
Following components on insert (1) must not be damaged:
Catches (2), top
Guides (3), bottom
Catches (4), bottom
Installation:
When installing, press insert (1) downwards in center.
Removing insert (glasses compartment) in carrier:

If necessary, open cover (1).
Press guide of cover (1) in middle with hand towards top and pull out
glasses compartmentÂ (2) approx. 2 mm.
Press glasses compartment (1) at outside left/right downwards a little
and pull out.
Installation:
Following components on bottom of glasses compartment (6) must
not be damaged:
Hold-down elements (1)
Guide (2)
Guides (3)
Catches (4)
Contacts (5)
Installation:
Catches (1) on top of glasses compartment (2) must not be
damaged.
Removing carrier:
Remove finisher for storage tray,
refer to 51 16 211.
Release screws (1).
Note:
If only switch (2) for ASC is fitted,
pull out carrier (3) a little.
If seat heating, rear window roller sun blind etc. are fitted, press out
switches from rear to front and disconnect plug connections.
Disconnect plug connections (1) for cigarette lighter and (2) for ASC and
remove carrier (3).
51 16 211 Removing and installing/replacing finisher for storage tray
Version with automatic transmission only:

Remove finisher for preselector lever,
refer to 51 16 210.
Jerkily remove knob (1) for selector lever towards top.

Lift out rubber gaiter (2).
Unscrew bolts (1).

Remove finisher (2) towards rear/top.
Disconnect plug connections and remove finisher (2).
Replacement only:
Unlock lock (1),
unscrew switch (2) towards top from support (3) and remove from finisher
(4) for storage tray.
Installation:
Check function.
51 16 202 Removing and installing/replacing front cup holder
Removal:
Press sides of oddments tray (1) together and lift out.
Cup holder (1) and oddments tray (2) are now unlocked from catches (3).
Remove cup holder (1) towards front/top and then remove oddments
tray (2).
Installation:
Guides (1) and supports (2) on left/right on cup holder (3) must not
be damaged.
Installation:
Guides (1) and supports (2) on left/right on oddments tray (3) must
not be damaged.
If necessary, replace fault tension spring (4).
Installation:
Insert oddments tray (1) at rear into center console.
Guide (2) must be positioned between supports (3) of centre console
(4), oddments tray (1) can now be snapped down into place.
Insert cup holder (1) into oddments tray (2).

Guides (3) must be positioned between supports of centre console (4),
cup holder (1) can now be snapped down into place.
Replacement only:
If necessary, lift out rubber tray (1) with special tool 00 9 316 (sealing lip
wedge) and remove.
51 16 340 Removing and installing/replacing glovebox lock
Unfasten screws (1) and remove upper (2) and lower sections of lock.
Insert vehicle key in lock cylinder (2).

Break open locks (1) if necessary and pull out lock cylinderÂ (2) with
vehicle key.
51 16 ... Removing and installing/replacing insert in storage tray
Removal:
Press together insert (1) at front on sides and remove towards top.
Insert (1) is now unlocked from supports (2).

Remove insert (1) towards front/top.
Installation:
Guides (1) and supports (2) on left/right on insert (3) must not be
damaged.
Installation:
Install insert (1) at rear in center console (4).
Guide (2) must be positioned between supports (3) of center console
(4), insert (1) can now be snapped towards bottom into place.
Replacement only:
If necessary, remove rubber trays (1) and (2) with special tool 00 9 316
(sealing lip wedge).
51 16 060 Removing and installing/replacing inside mirror (with cable ”X”
and connector cover)
Important!
18 ... 28 °C.
30 minutes).


Check compass function after replacement or after disconnecting inside
mirror plug connection or battery.
Important!
Pry out connector cover in direction of arrow and disconnect plug

connection beneath it.
Important!
mirror mount.
Installation note:
Only replace with version with remote key for central locking system:
Initialise all transmitters (ignition keys), refer to Owner's Handbook.
51 16 060 Removing and installing/replacing inside mirror (with full base)
Important!
18 ... 28 °C.
30 minutes).
Important!
Important!
mirror mount.
Installation note:
51 16 060 Removing and installing/replacing inside mirror (with mirror arm
end caps)
Important!
18 ... 28 °C.
30 minutes).


Important!
Note:
Do not exert any pressure on mirror base when removing end caps (1).
Press end caps (1) towards mirror housing (2); this releases clip
connection of both end caps (1).
In order not to create any tension at the mirror base, simultaneously
apply counterpressure to the mirror housing when removing the end
caps.
Twist inside mirror (1) at an angle towards front and right/top.

Swivel left end cap (2) off ball neck in direction of arrow; this detaches the
engagement clip (3) from the metal foot.
Twist inside mirror (1) at an angle towards front and left/top.
Swivel right end cap (2) off ball neck in direction of arrow; this detaches
the engagement clip from the metal foot.
Installation note:
Clips (1) and retaining hooks (2) of end caps (3) must not be damaged,
Version with cable (X):

Important!
mirror mount.
Installation note:
Only replace with version with remote key for central locking system:
Initialise all transmitters (ignition keys), refer to Owner's Handbook.
51 16 060 Removing and installing/replacing inside mirror (with rain sensor)
Important!
18 ... 28 °C.
30 minutes).



Important!
Press on end caps (1) and at same time press them apart; this releases
clip connection of both caps (1).
Twist inside mirror (1) at an angle towards front and right/top.

Swivel left end cap (2) off ball neck in direction of arrow; this detaches the
engagement clip (3) from the metal foot.
Twist inside mirror (1) at an angle towards front and left/top.
Swivel right end cap (2) off ball neck in direction of arrow; this detaches
the engagement clip from the metal foot.
Installation note:
Clips (1) and retaining hooks (2) of end caps (3) must not be damaged,

Note:
Pay attention to cable routing (2) for rain sensor.

Important!
mirror mount.
Installation note:
Only in case of replacement with version with remote control for

central locking:
If necessary, initialise all transmitters (ignition keys), refer to Owner's
Handbook.
51 16 060 Removing and installing/replacing interior rearview mirror
(overview)
Note:
Version with cable (X) for:
Automatic dim action (electro-chrome technology) for interior
rearview mirror
Condensation sensor
Remote control (infrared or radio)
High-beam assistant
Garage door openers
Compass
Rain sensor
Version without cable (X) with full foot (1).
Version with cable (X) and plug trim cover (1).
Version with mirror arm end caps (1).

Version with rain sensor.
Version with Autobeam.
Version with toll mirror for Japan.

51 16 450 Removing and installing/replacing rear left/right grab handle

Removing and installing/replacing front grab handle.
51 16 000 Removing and installing/replacing rear-view mirror on left or right
front door
Partly remove cover (anti-trapping protection) at front from inside of

door window frame,
refer to 51 32 160.
Version with loudspeaker:

Release screws (2) and remove speaker (3).
Installation:
Tightening Torque,
Check function
Remove rearview mirror (1) and feed out cable (2).

51 16 221 Replacing a clipped cover (decorative strip on front or rear door)
(Saloon, Touring)

00 9 321
Warning!
Version with side airbag:
Note safety information for working on vehicles with airbag systems,
see 51 00 ...
Decorative strip on front door:

Insert special tool 00 9 321 (folding leg) from the side and use a second
special tool 00 9 321 (folding leg) close to the retaining bolts,
see next work operation,
to unclip the decorative strip (1).
Installation note:
If necessary, replace faulty bolts (1) on the decorative strip (2).
Version with real wood:Installation note:

If necessary, replace faulty screw-in pins (1) on the decorative strip (2).
If necessary, make sure the screws (3) are correctly seated.
Installation note:
Slide in the decorative strip (1) with the guides (2) into the handle recess
(3) and then clip in.
Installation note:
If necessary, replace faulty grommets (1) on the door trim panel (2).
Decorative strip on rear door:

Insert special tool 00 9 321 (folding leg) from the side and use a second
special tool 00 9 321 (folding leg) close to the retaining bolts,
see next work operation,
to unclip the decorative strip (1).
Installation note:
If necessary, replace faulty bolts (1) on the decorative strip (2).
Version with real wood:Installation note:
If necessary, replace faulty screw-in pins (1) on the decorative strip (2).
If necessary, make sure the screws (3) are correctly seated.
Installation note:
Slide in the decorative strip (1) with the guides (2) into the handle recess
(3) and then clip in.
Installation note:
If necessary, replace faulty grommets (1) on the door trim panel (2).
51 16 221 Replacing a clipped-in trim (decorative strip on panel for
instrument panel, front or rear door)

00 9 321
Replacement of: Decorative strip on front or rear door or side trim

panel.
Warning!
Version with side and passenger airbags:
Follow safety instructions for working on cars with airbag systems,
refer to 51 00 ...
Warning!
Incorrect combination of pin and clip (Hutfix):
the decorative strip may come loose when the passenger airbag is
triggered (risk of injury).
The pins must therefore always be measured.
Caution!
Decorative strips above glovebox,
on light switch and above radio
are secured with different pins and clip (Hutfix).
On all cars without screw (1):

the clips (2) of instrument panel are "white"
the pins of decorative strip are "yellow"
the pins must have a diameter of 5.7 mm (always measure)
The decorative strips for replacement are always supplied with a pin
diameter of 6.0 mm,
these pins must be replaced by 5.7 mm dia. pins.
On all cars with screw (1):
the clips (2) of instrument panel are "red"
the pins of decorative strip are "red" or "plain"
the pins must have a diameter of
6.0 mm (always measure)
Replacing clips (Hutfix) on instrument panel:
A Use screwdriver to turn clip (1) through approx. 30° to left
B Lever out clip (1) from below
Installation:
Retainers (1) on clip (2) must not be damaged.
Do not damage support (3) in instrument panel (4).
Installation:
A Insert clip (1) from above and snap into place at bottom
Use screwdriver to turn clip (1) through approx. 30° to right
B Clip (1) in end position
Decorative strip on light switch:

Caution!
Carefully unclip decorative strip with two special tools 00 9 321
(fishbone) (risk of damage).
Insert special tool 00 9 321 (fishbone) at side and with second special
tool 00 9 321 next to retaining pin,
refer to next work step,
unclip decorative strip (1).
Installation:
If necessary, replace faulty pins (1) of decorative strip (2).
Always replace clips (Hutfix) on instrument panel.
Observe color matching,
refer to first work step.
Model with real wood:Installation:

If necessary, replace faulty screw-in pins (1) on decorative strip (2).
Installation:
Push guides (1) onto locators (2).
Decorative strip above glovebox:

Caution!
Carefully unclip decorative strip with two special tools 00 9 321
(fishbone) (risk of damage).
Insert special tool 00 9 321 at side and with second special tool 00 9 321
next to retaining pin,
refer to next work step,
unclip decorative strip (1).
Installation:
If necessary, replace faulty pins (1) of decorative strip (2).

Decorative strip above radio:

Remove decorative strip above glovebox.
Unclip decorative strip (1) with special tool 00 9 321 (fishbone) (risk of
damage).
Installation:
If necessary, replace faulty pin (1) on decorative strip (2).
Check that screws (3) on bracket (4) are properly seated.
Installation:
Push guides (1) into locators (2).
Clip in decorative strip completely.
51 16 ... Replacing left or right outside mirror housing
Remove mirror glass,

refer to 51 16 026.
Tilt exterior rearview mirror towards front.

Note:
Unlock catch (2) with special tool 00 9 321 (folding leg).
Unlock catches (1) and (2) and remove housing.
Installation:
Catches on casing (2) must not be damaged.
Tilt exterior rearview mirror fully forward again.

Release screws (1).
Lift out catches (2) and
remove "housing frameâ€� (3).
Installation:
Catches (1) on housing frame (2) must not be damaged.
Check function.
51 16 026 Replacing mirror glass for rear-view mirror (on front door)
Caution!Make sure car has room temperature to prevent the clips

from breaking off.
Tilt mirror glass.

Remove cement between mirror glass and edge of housing (risk of
damage).
Unclip mirror glass using a wooden wedge.

If applicable, remove connector (mirror glass heating) and remove mirror
glass.
Installation:
Install mirror glass that clips are seated on tabs and clip on glass.
Ensure correct engagement.
Check function.
51 16 361 Replacing right glovebox
Remove lock for right glovebox.

Remove right glovebox.
51 16 201 Replacing storage tray
Version with car phone:

Remove phone handset with keypad,
refer to 84 11 500.
Remove interface for D-Net car phone,
refer to 84 11 530.
Version without car phone:

Remove storage tray,
refer to 51 16 200.
Remove insert in storage tray,
refer to 51 16 ...
Version with cup holder:
Remove front cup holder,
refer to 51 16 202.
Press switch for hazard warning lights/central locking from below out of
storage trayÂ (1).
51 17 400 Removing and installing/replacing bump stop with ejector for filler
flap
Release cover (1).

Press catches (2) together and pull out ejector (3).
Installation:
Install ejector (3) with fitted cover (1).
Installation:
Catches (1) on ejector (2) must not be damaged.
Make sure cover (3) is correctly seated on ejector (2).

Note:
E30
E31, E32, E34, E36, E38, E39
E46, E52, E53, E60, E61, E63, E64, E65, E66, E67, E84, E85, E86,
E90, E91, E92, E93


flush with housing.
(A) OK
(B) not OK
tool (1).
OK.
51 21 004 Adjusting front left or right door detent (lock wedge)

Adjusting left or right front door.
51 21 150 Blocking, if necessary initialising, car key in immobiliser control
module
Note:
Execution in diagnosis system:
->Service functions->
‐>Body->
‐>Locking and security functions‐>
‐>Remote control key

Note:
E30
E31, E32, E34, E36, E38, E39
E46, E52, E53, E60, E61, E63, E64, E65, E66, E67, E84, E85, E86,
E90, E91, E92, E93


flush with housing.
(A) OK
(B) not OK
tool (1).
OK.
51 21 181 Removing and installing cover on outside handle with locking
cylinder

Remove and install/replace complete locking cylinder from left or right
front door,
refer to 51 21 140.
.
51 21 280 Removing and installing or replacing door stop on left or right
front door
Remove sound insulation in front area only,

refer to 51 48 ...
Raise the door window.
Unscrew bolt (1).

Remove seal (2) towards rear and detach from door brake (3).
Note:
For removal, fold back screw plate (1).
Release screws (2) and feed out door brake (3) to inner door
panel.Installation:
If necessary, stick butylene tape (sourcing reference: BMW Parts
Service) between door stop and inner door plate.
Installation:
To install door brake (1), fold back screw plate (2) as shown in
illustration.
51 21 300 Removing and installing or replacing window cavity cover strip on
outside of left or right front door

00 9 324
Important!
Observe procedure for using special tool 00 9 324 .
Important!
If reusing the existing window cavity cover strip (1), make sure it is
not bent.
Lever out window cavity cover strip (1) with special tool 00 9 324 (starting
at B-pillar).
Pull window cavity cover strip (1) out of door mirror (2) in direction of
arrow.Installation:
Coat window cavity cover strip (1) with water before fitting.
Window cavity cover strip (1) must be flush at rear to door edge.
Installation:
Seal (1) must be correctly fitted in cover strip (2).
51 21 140 Removing and installing/replacing complete lock cylinder in left or
right front door
Compact only:
Lever out cover (1).
Note:
2 Cover for outside handle
3 Cover for adjusting door lock
Convertible/coupé only:
Only lever out cover (1) to such an extent that bore (2) is accessible.
Saloon/sedan/touring only:
Lever out trim (1).
Installation:
Fit new plate (1).
All models:
Release screw (1).
Note:
Thread of screw (1):
M6 Build date up to 09/00
M5 Build date from 09/00
Removing cover (1) on outside handle:
A Pull cover (1) approx. 1 to 2 mm towards rear.
B Detach cover (1) with lock cylinder (2) towards outside.
Installation:
Notch (2) on paddle mount (1) must be secured in catch (3).
Only in this position will installation of the lock barrel be guaranteed.
Replacement only:
Lever out catches (1) and detach cover (2) from lock cylinder (3).
Installation:
Catches (1) on cover (2) must not be damaged.
3 Lock cylinder
51 21 180 Removing and installing/replacing cover on outside handle
coupÃ©:
Lever out cover (1) only until bore (2) is accessible.
sedan:
Remove plate (1).
Installation:
Fit new plate (1).
Unscrew bolt (1).

Detach cover (2).
Lever out catches (1) and detach cover (2) from filler element
(3).Installation:
51 21 090 Removing and installing/replacing door lock in left or right front
door (from 09/00)
Note:
The work is identical for all E46 models from year of manufacture 09/2000.
The components are simply adapted to the different door geometries.
A 4 mm WAF Allen key is required for adjustment.

Remove acoustic insulation
Driver's side only:
Remove complete lock cylinder
Only Coupé/Convertible:
Remove rear section of power window unit
Disconnect plug connection (1) on door lock (2).
Lever out Bowden cable (1) from holder (2) with screwdriver.
Important!
Do not bend holder (2).
Unhook Bowden cable nipple (3) from lever (4).

Release screws (1).
Remove door lock (2) with linkage (3).
Installation:
Insert linkage for locking knob through opening in inner door plate.
Do not bend linkage (3).
Replace screws (1).
Important!
Do not close door while installing door lock and lock barrel.
It is not possible to open the door when the adjusting screw is
released.
Secure door against closing.
Installation:
Left door lock of front door:
Slacken adjusting screw (1) on door lock (2) (turn in counterclockwise
direction, as shown in illustration) - this makes the Bowden cable
mount (3) movable.
Coupé/Convertible:
For the Coupé, the door lock (4) is adapted to the different door
geometry.
The illustration shows the left driver's door lock.
The adjusting procedure is identical to that for the Saloon.
Important!
Spring (3) must be fitted and must not be damaged.
1 Bowden cable holder for outside door handle

2 Adjusting screw (4 mm WAF)
Installation:
Right door lock of front door:
Slacken adjusting screw (1) on door lock (2) (turn in clockwise direction,
as shown in illustration) - this makes the Bowden cable mount (3)
movable.
Note:
The Bowden cable mount (3) is still shown in the illustration as lock
lever (3), but is similar to that in Fig. R51 2804.
Coupé/Convertible:
Lever out sealing cap (1) for following adjustment.
Installation:
After installing lock cylinder (51 21 140) and/or cover (51 21 180),
lever out sealing cap (2).
Tighten down adjusting screw (2) on door lock and fit sealing cap (1).
Direction of rotation of adjustment screw (1):
Front left door Front right door

Tighten down adjusting screw (1) in Tighten down adjusting screw
clockwise direction, as shown in (1) in counterclockwise
illustration. direction.
Important!
Carry out function check only with door open.
If door is closed
and the setting at the rotary striker lock is incorrect,
it may not be possible to open door any more
and the door trim panel must be destroyed.
Checking unlocking of rotary striker lock:
Close rotary striker lock (1) with a screwdriver,
lock car with car key,
unlock car with car key,
open rotary striker lock (1) with outside door handle,
if rotary striker lock (1) opens, then O.K.
If rotary striker lock (1) fails to open,
slacken adjustment screw (2) again,
Retighten adjusting screw (2),
Carry out check again.
Fit sealing cap.
Checking overtravel at outer handle:

Close rotary striker lock with a screwdriver,
open rotary striker lock with outside door handle (1),
outside door handle (1) must be able to open further by
measurement (A),
if measurement (A) is obtained, then O.K.
if measurement (A) is not obtained, readjust rotary striker lock and
carry out overtravel check,
if measurement (A) is still not obtained, you must Bowden cable
with carrier.
A At least 2 mm
Important!
Door striker (lock wedge) must not be greased.
Door lock does not have to be greased until after 100,000 km.
Only replace:
Lift out lock (1) and detach Bowden cable (2) from fixture (3).
Remove Bowden cable nipple (4) from lever (5).
Note:
The Bowden cable mount for the inside door handle is the same for all
construction versions. The construction version up to 09/2000 is shown
here.
Only replace:
Turn linkage for locking knob (1) and detach from lever (2).
Installation:
Following parts must not be damaged:
1 Mount for paddle of lock barrel (driver's side only)
2 Mount for Bowden cable of outside door handle
3 Mount for Bowden cable of inside door handle
The illustration shows the left driver's door lock on the Saloon.
Installation:
1. Spring
2. Mount for Bowden cable of inside door handle
3. Mount for linkage of locking button
4. Mount for paddle of lock barrel (driver's side only)
The illustration shows the left driver's door lock on the Coupé.
51 21 090 Removing and installing/replacing door lock in left or right front
door (to 09/00)
Note:
The operation is identical for all E46 up to model year 09/2000.
Components are simply adapted to different door geometries.
A 4 mm WAF hexagon socket wrench is required for adjustment.
Detach rear window lift rail (do not remove).
Driver's side only:
Remove complete lock cylinder.
Note:
Only Coupé to 25/05/1999:
In case of door lock malfunction,
Refer to Service Information.
Release screws (1).

Installation:
Insert linkage for locking knob through opening in inner door plate.
Make sure that lock lever is inserted between outer door handle carrier
and outer skin.
Replace screws (1).
Important!
Do not close door while installing door lock and lock barrel.
released.
Installation:
Left door lock of front door:
Slacken adjusting screw (1) on door lock (2).
(turn counterclockwise, as shown in graphic),
so that lock lever (3) can be moved.
Coupé/Convertible:
For Coupé, door lock (2) is adapted to different door geometry.
Illustration shows left driver's door lock.
Adjusting procedure is identical to that for Saloon.
Important!
Spring (4) on lock lever (3) must be fitted and must not be
damaged.
1 Adjusting screw (4 mm WAF)
Installation:
Right door lock of front door:
(turn clockwise, as shown in graphic),
Coupé/Convertible:
Installation:

Important!
If door is closed

Fit sealing cap.

measurement (A),
if measurement (A) is still not obtained, you must replace the door
lock.
A At least 2 mm
Important!
Door striker (lock wedge) must not be greased.
Only replace:
Only replace:
Turn linkage for locking knob (1) and detach from lever (2).
Installation:
1. Spring
2. Mount for Bowden cable of inside door handle
3. Mount for linkage of locking button
4. Mount for paddle of lock barrel (driver's side only)
The illustration shows the left driver's door lock on the Coupé.
51 21 170 Removing and installing/replacing outer door handle of left or
right front door (09/00 and later)

00 9 322
Note:
The work is identical for all E46 models from model year 09/2000.
Components are simply adapted to different door geometries.
Driver's side:
Remove lock barrel completely from front door.
Passenger's side:
Remove cover on outer door handle.
Removal:
Move lock actuation unit into "working position"
Pull outer door handle (1) outward/upward and secure with special tool
00 9 322 .
In this position, tighten bolt (2) in counterclockwise direction (left-hand
thread).
Now, the lock actuation unit is in "working position".
Installation note:

Note:
Turn driver and front passenger side in same direction.
3 Bolt for lock barrel
Pull outer door handle (1) out.

Remove outer door handle (1) rearward/outward from the front
door.Installation note:
If the outer door handle (1) cannot be installed, then the lock actuation
unit is not in the "working position".
Installation note:
Bore hole (1) and guide (2) on the outer door handle (3) must not be
damaged.
Only replace:
Remove seals (1) and (2) for outer door handle.
Installation: Note:
For the installation of the outer door handle, the lock mechanism must be
in the "working position".
"Working position":
The distance between the holder (1) of the lock actuation unit (2) and the
outer door panel must not exceed dimension (A).
A <8 mm
If dimension (A) is greater, then pull the mount (1) out with a finger until
dimension (A) is reached.
Insert outer door handle (1).
The elevation of the seal (2) must not be crushed by the outer door
handle (1).
Coupé/Convertible:
Installation note:
After installing lock barrel (51 21 140) and/or cover (51 21 180),
Tighten adjusting screw (1) on door lock.
Direction of rotation of adjusting screw (1):

Attention!
Carry out function and overtravel check only with door open.
If the door is closed,
it may no longer be possible to open doors
lock vehicle with car key,
unlock vehicle with car key,
open rotary striker lock (1) with outer door handle,
slacken adjusting screw (2) again,
Fit sealing cap.
Checking overtravel at outer door handle:

open rotary striker lock with outer door handle (1),
outer door handle (1) must be able to open further by dimension
(A),
if dimension (A) is obtained, then O.K.
if dimension (A) is not obtained, readjust rotary striker lock and carry
out overtravel check,
if dimension (A) is still not obtained, you must Bowden cable with
support.
A At least 2 mm
51 21 200 Removing and installing/replacing outside handle and lock
actuation of left or right front door (starting 09/00)
Note:
Beginning in model year 09/2000, the lock actuation unit has a
Bowden cable.
Remove acoustic insulation.
Remove outer handle.
Lever out seals (1) and (2) for outer door handle.
Important!
Expose Bowden cable (1) on Limousine and Touring:

Remove Bowden cable (1) from the guide (2).
Installation:
The foam (3) must be in the area of the guide (2).
Note:
Represented in the picture without window guide rail.
Expose Bowden cable (3) on Coupé and Convertible:
To do this, disengage the latch mechanisms (1) and remove guide (2).
Note:
The guide (2) is depicted on the right front door.
Installation:
The latch mechanisms (1) and mounting (2) of the guide (3) must not be
damaged.
Note:
Guide of the right front door depicted.
Expose Bowden cable (3) on the Compact:

To do this, disengage the latch mechanisms (1) and remove guide (2) in
upward direction.
Installation:
The latch mechanisms (1) and mountings (2) of the guide (3) must not be
damaged.
Loosen bolt (1).
Lever out lock actuator (2) towards front and remove to inner door plate.
Note:
2-door and 4-door models have different locking systems.
The locking systems differ in their Bowden cable nipple.
Bowden cable nipple (1) for 4-door models.
Bowden cable nipple (2) for 2-door models.
Installation:
The grommet (3) must be pushed onto the end piece (4).
Installation:
If necessary, replace bolt (1) on lock actuation unit (3).
The Bowden cable (2) must be correctly latched with the lock actuation
unit (3).
Installation:
The Bowden cable nipple (1) must be correctly installed in the lock
actuation unit (2) and must not be removed.
actuator on left or right front door (up to 09/00)
Remove door lock on front door.

Remove outside handle on front door.
Remove seals (1) and (2) for outside handle.
Loosen bolt (1).

If necessary, replace screw (1) on lock actuator (2).

51 21 170 Removing and installing/replacing outside handle on left or right
front door (up to 09/00)
Note:
The work is identical for all E46 models up to year of manufacture
09/2000.
The components are simply adapted to the different door
geometries.
Driver's side:
Remove lock cylinder completely from front door.
Passenger side:
Remove cover on outside handle.
Removal:
Pull outside handle (1) max. outwards and approx. 2 mm towards rear.
Note:
The lock mechanism is now engaged.
(A):
Press outside handle (1) approx. 4 mm towards inside.
(B):
Remove outside handle (1) towards rear/outside.
Installation:
Guide (1) and support (2) on outside handle (3) must not be damaged.
Replacement only:
Installation:
For installation of the outside handle, the lock mechanism (1) must be
engaged on the outside (as shown in illustration).
Installation of outside handle possible.
If the lock mechanism (1) is on the inside (as shown in illustration), the
outside handle cannot be fitted.
For installation, the lock mechanism (1) must be moved to the installation
position.
If necessary, move lock mechanism (3) outwards/towards rear to

installation position through bore (1) with a screwdriver (2).
Insert outside handle (1) and snap towards front into place (audible click).
Coupé/convertible:
Installation:
Lever out sealing cap (2).
Tighten adjusting screw (1) on door lock.

Caution!
Carry out function and overtravel checks only when door is open.
If door is closed
door cannot be opened any more
carry out check again.
Fit sealing cap.
Checking overtravel at outside handle:

measurement (A),
if measurement (A) is still not obtained, you must replace door lock.
A min. 2 mm
51 21 330 Removing and installing/replacing window cavity cover strip on
inner front door
Remove front door trim panel,

refer to 51 41 000.
Remove window cavity cover strip (1) towards top.Installation:

If necessary, remove faulty clips (2) from inner door panel and
replace.
Installation:
Prior to installation, coat window cavity cover strip (1) with soapy
solution (washing-up liquid).
Begin installation at front.
51 21 ... Removing weather strip with special tool 00 9 324 at front or rear

00 9 318
00 9 324
Open side window completely.
Front door:
Insert special tool 00 9 324 at front (at A-pillar) in window cavity (1) (TOP
label pointing upwards).
Rear door:
Insert special tool 00 9 324 at rear (at C-pillar) in window cavity (2) (TOP
label pointing upwards).
Note:
For purposes of clarity, graphic shows inner door panel and side window
removed.
Special tool 00 9 324 must be correctly guided under window cavity

cover strip (1).
2 Short leg, bottom
3 Long leg, top (TOP)
Note:
Start at the front or rear, depending on the model.
Important!
Risk of damage!
Raise weather strip (3) no more than 5 mm in each levering
operation, otherwise the strip will be bent.
Position special tool 00 9 318 on door trim panel (1).

Slide screwdriver (2) via the special tool 00 9 324 and lever window
cavity cover strip (3) upwards no more than 5 mm.
Guide special tools 00 9 324 and 00 9 318 towards front/rear and lever
out the window cavity cover strip (3).
51 21 182 Replacing cover on outside handle with locking cylinder

Remove and install/replace complete locking cylinder from left or right
front door,
refer to 51 21 140.
.
51 21 003 Replacing door detent (lock striker), front left or right
Lift off cover (1).
Unscrew bolt (1).Note:

Screw in threaded pin so that thread plate does not drop into door
pillar.
Release screw (1) and remove lock striker (2) with seal (3).Installation:
Adjust lock striker (2).
51 21 145 Replacing locks for simultaneous closing
Replace locking cylinder for steering lock,

refer to 32 32 050.
Replace lock for right glovebox,
refer to 51 16 340.
Replace complete locking cylinder in front door,
refer to 51 21 140.
Replace lock for rear lid,
refer to 51 24 050.
.
51 21 146 Replacing locks for simultaneous closing with EWS control
module
Replace locks for simultaneous closing,

refer to 51 21 145.
Remove panel for pedals,
refer to 51 45 185.
- Disconnect battery negative lead

- Disconnect plug connection on control module for electronic immobilizer
and remove control module
- Install new control module
- Connect battery negative lead
- Connect DIS Tester or MoDiC III

- Select model
- Select coding program
- Read out data
- Code EWS control module
- Terminate coding program
- Carry out function check
51 22 004 Adjusting rear left or right door lock striker

Adjusting left or right rear door.
51 22 180 Removing and installing/replacing cover on outside handle, left or
right
Lever out cap (1).
Unscrew bolt (1).

Detach cover (2).
Lever out catches (1) and detach cover (2) from filler element
(3).Installation:
51 22 090 Removing and installing/replacing door lock in left or right rear
door (from 09/00)
Note:
The operation is identical for all E46 4-door models from model year
09/2000.
Close the door window.
Remove sound insulation in rear door.
Installation:
Check function of child safety catch, as problems may arise:

Lock does not centre in body aperture
Lock scrapes on inner door panel
Lock snags on inner door panel
Important!

Release screws (1).
Installation:
Insert linkage for locking button through opening in inner door panel.
Replace screws (1).
Important!
Do not close door while installing door lock and cover barrel.
released.
Installation:
Left door lock of rear door:
(turn anti-clockwise, as shown in graphic),
so that Bowden cable connection (3) can be moved.
Installation:
Right door lock of rear door:
so that Bowden cable connection (3) can be moved.
Note:
The Bowden cable connection (3) is still shown in the graphic as lock
lever (3), but is similar to that in Fig. R51 2807.
Installation:
Link rear door Right rear door

clockwise direction, as shown in (2) in anti-clockwise direction.
illustration.
Important!
If door is closed

lock vehicle with ignition key,
unlock vehicle with ignition key,
Fit sealing cap (3).
Checking overtravel at outside door handle:

measurement (A),
lock.
A At least 2 mm
Important!
Door lock and lock striker must not be greased.
Only replace:
Note:
The Bowden cable connection for the inside door handle is the same for
all construction versions. The version up to 09/2000 is shown in the
graphic.
Only replace:
Turn linkage for locking button (1) and detach from lever (2).
51 22 090 Removing and installing/replacing door lock in left or right rear
door (up to 09/00)
Note:
The operation is identical for all E46 4-door models up to model year
09/2000.
Remove sound insulation in rear door.
Installation:
Check function of child safety catch, as problems may arise:

Lock does not centre in body aperture
Lock scrapes on inner door panel
Lock snags on inner door panel
Release screws (1).

Installation:
Insert linkage for locking button through opening in inner door panel.
Make sure that lock lever is inserted between outer door handle carrier
and outer skin.
Replace screws (1).
Important!
Do not close door while installing door lock and cover barrel.
released.
Installation:
Left door lock of rear door:
(turn anti-clockwise, as shown in graphic),
Installation:
Right door lock of rear door:
Installation:

clockwise direction, as shown in (2) in anti-clockwise direction.
illustration.
Important!
If door is closed

measurement (A),
lock.
A At least 2 mm
Important!
Door lock and lock striker must not be greased.
Only replace:
Only replace:
Turn linkage for locking button (1) and detach from lever (2).
51 22 280 Removing and installing/replacing door stop on rear left or right
door

Note:
To release or partially detach sound insulation, follow procedure in
”Removing and installing/replacing sound insulation on front left or
right door”,
refer to 51 48 ...
Partially detach sound insulation at front and secure with adhesive tape
(1).
Unscrew bolt (1).

Remove seal (2) towards rear and detach from door brake (3).
Note:
For removal, fold back screw plate (1).
Release screws (2) and feed out door brake (3) to inner door
panel.Installation:
If necessary, stick butylene tape (sourcing reference: BMW Parts
Service) between door stop and inner door plate.
Pull door stop (2) out of rubber sleeve (1).

Installation:
To install door brake (1), fold back screw plate (2) as shown in
illustration.
51 22 170 Removing and installing/replacing outer door handle in left or
right rear door (up to 09/00)
Note:
The operation is identical for all E46 4-door models up to model year
09/2000.
Remove cover on outer door handle
Removal:
Pull outer door handle (1) all the way out and approx. 2 mm back.
Note:
The lock mechanism is now locked.
(A):
Press outer door handle (1) approx. 4 mm inward.

(B):
Pull outer door handle (1) back/out.
Installation note:
Mounting (2) and guide (1) on outer door handle (3) must not be
damaged.
Only replace:
Remove seals (1) and (2) for outer door handle.
Installation:
For installation of outer door handle, outer lock mechanism (1) must be
locked (as illustrated in image).
Installation of outer door handle possible
If the lock mechanism (1) is on the inside (as illustrated in image) outer
door handle cannot be installed.
For installation, the lock mechanism (1) must be placed in working
position.
If necessary, use angled slotted screwdriver (1) to bring the lock

mechanism (2) outside/to the rear in working position.
Guide in outer door handle and push forward to lock (audible click).
Installation note:

Important!
the door can no longer be opened

lock vehicle with car key,
unlock vehicle with car key,
open rotary striker lock (1) with outer door handle,
Checking overtravel at outer door handle:
open rotary striker lock with outer door handle (1),
outer door handle (1) must be able to open further by dimension
(A),
if dimension (A) is obtained, then O.K.
if dimension (A) is not obtained, readjust rotary striker lock and carry
out overtravel check,
if dimension (A) is still not obtained, you must replace the door lock.
A At least 2 mm
actuation of rear door (from 09/00)
Note:
From model year 09/2000, lock actuation has Bowden cable.
Remove acoustic insulation.
Remove outside handle on rear door.
Lift out seals (1) and (2) for outside handle.
Important!
Feed Bowden cable (1) out of guide (2).Installation:

Foam (3) must be in region of guide (2).
Note:
Shown in figure without window guide rail.
Loosen bolt (1).
Installation:
Grommet (3) must be pushed onto end piece (4).
Note:
Bowden cable nipple (1) for rear door.
Bowden cable nipple (2) only for front door of 2-door model.
Installation:
If necessary, replace screw (1) on lock actuation (3).
Bowden cable (2) must be correctly engaged with lock actuation (3).
Installation:
Bowden cable nipple (1) must be correctly installed in lock actuation (2)
and may not be disassembled.
activator of rear door left and right (up to 09/00)
Remove door lock on rear door

Remove outside handle on rear door
Loosen bolt (1).

Lift lock activator (2) to the front/down from the window guide and remove
from the door inner trim.
If necessary, release screw (1) on lock activator (2).

51 22 170 Removing and installing/replacing outer door handle in left or
right rear door (from 09/00)

00 9 322
Note:
The operation is identical for all E46 4-door models from model year
09/2000.
Remove cover on outer door handle
Removal:
Move lock actuation unit into "working position"
Pull outer door handle (1) outwards/upwards and secure with special tool
00 9 322 .
In this position, tighten bolt (2) in counterclockwise direction (left-hand
thread).
Now, the lock actuation unit is in "working position".
Installation:

Note:
Turn driver and front passenger side in same direction.
3 Bolt for lock barrel
Pull outer door handle (1) out.
Remove outer door handle (1) rearward/outward from the front

door.Installation:
If the outer door handle (1) cannot be installed, then the lock actuation
unit is not in the "working position".
Installation:
Bore hole (1) and guide (2) on the outer door handle (3) must not be
damaged.
Only replace:
Lever out seals (1) and (2) for outer door handle.
Installation: Note:
For the installation of the outer door handle, the lock mechanism must be
in the "working position".
"Working position":
The distance between the holder (1) of the lock actuation unit (2) and the
outer door panel must not exceed dimension (A).
A < 8 mm
If dimension (A) is greater, then pull the mounting (1) out with a finger until
dimension (A) is reached.
Insert outer door handle (1).

The elevation of the seal (2) must not be crushed by the outer door
handle (1).
Installation:

Important!
the door can no longer be opened


measurement (A),
lock.
A At least 2 mm
inside rear door
Remove rear door trim,

refer to 51 42 000.
Note:
Do not damage cover (2) when removing window cavity cover
stripÂ (1).
Remove window cavity cover strip (1) towards top.Installation:

If necessary, remove faulty clips (3) from inner door panel and
replace.
Installation:
Prior to installation, coat window cavity cover strip (1) with soapy
solution (washing-up liquid).
Installation:
Window cavity cover strip (1) must (as shown in illustration) be
above cover (2) for door window frame.
rear door on left or right

00 9 324
Important!
Observe procedure for using special tool 00 9 324 .
Important!
If reusing the existing window cavity cover strip (1), make sure it is
not bent.
Lever out window cavity cover strip (1) with special tool 00 9 324 (starting
at B-pillar).
Installation:
Seal (1) must be correctly fitted in cover strip (2).
51 22 001 Replacing door detent (lock striker), rear left or right

Replace door detent (lock striker), front left or right,
refer to 51 21 003.
.
51 23 ... Adjusting/replacing bump stops
The illustrations are schematic representations and are to be applied to

the relevant vehicle type.
Version 1:
(1) Bump stop
Adjust bump stop (1) to correct height by turning left or right.
Version 2:
Replace damaged bump stops (refer to EPC):
(1) Bump stop with ejector
Press ejector (1) into bump stop and, in this position, twist approx. 90°
counterclockwise with a Phillips screwdriver.
This locks the ejectors (1) in the bump stops.
Unlock the ejector (1) again after completing adjustment.
Version 3:
(1) Bump stop
Turn lock (1) 45° counterclockwise.

Pull bump stop (2) upwards.
Close lid slowly until it is at the same height as the side panel.
Open lid and turn lock (1) clockwise.
Installation:
Press bump stop into panel and drive in expanding pins (3).
The graphics are schematic representations and are to be applied to the

relevant vehicle type.
Prerequisite: Lid must be correctly adjusted.

(1) Bump stop
(2) Catches
Remove adjusting buffer by pressing latch mechanisms back.
Screw adjusting buffer (1) until the pin (2) can be pulled out.
Slowly pull the pin (2) out approx. 15 mm.
Slowly close engine compartment lid.
The pin (2) is thus pushed into the adjusting buffer (1).
Raise engine compartment lid.

Unscrew the adjusting buffer (1) until it is flush with the upper edge of the
pin (2).
51 23 265 Removing and installing/replacing left or right gas pressure spring
for engine compartment lid
Warning!
Risk of injury and damage!
For the following tasks, you must take the appropriate measures to
support the engine compartment lid.
As an alternative, you can enlist the help of a second person to
hold the engine compartment lid.
Raise engine compartment lid.

Disassembling ball socket (1).
Unclip gas spring strut (3) in direction of arrow from ball stud (2), top and
bottom.
Detach gas pressurised prop.
51 23 ... Removing/installing ball sockets with clip
Warning!
Danger of injury! When installed, the gas pressurised shock
absorber is under preload. Minimise preload as far as possible
before removing.
Important!
Never lift off ball socket with engaged clamp.
Disassembly/assembly:
1. Push on clamp in direction of groove with screwdriver
2. Lift off ball socket from ball pin
3. Slide clamp back
4. Fit ball socket on ball stud and snap into place with force
Installation note:
Pack grease into two opposite positions in socket. The grease spreads
after installation on the ball pin all round in the ball socket.
The illustrations are schematic representations and are to be applied to

the relevant vehicle type.
Version 1:
(1) Bump stop
Version 2:
(1) Bump stop with ejector
Press ejector (1) into bump stop and, in this position, twist approx. 90°
counterclockwise with a Phillips screwdriver.
This locks the ejectors (1) in the bump stops.
Unlock the ejector (1) again after completing adjustment.
Version 3:
(1) Bump stop
Turn lock (1) 45° counterclockwise.

Pull bump stop (2) upwards.
Close lid slowly until it is at the same height as the side panel.
Open lid and turn lock (1) clockwise.
Installation:
Press bump stop into panel and drive in expanding pins (3).
51 24 145 Removing and installing/replacing button for rear lid actuation

Replacing handle strip (on rear lid)
51 24 050 Removing and installing/replacing lock (lock cylinder) for rear lid
Remove panel for rear lid.

Unlock lock (2) and remove socket housing (3) for tail light.
Release nut (1) and remove clamping piece (2).
Raise tail light (1) a little and remove with guidesÂ (2) facing outwards
from trunk lid (3).
Detach cable (1) from cover (2).

Lever cover (1) off clip (2).
Detach and remove cover (1) from guides (3) on metal.

Pull off lock (2) and lever actuating rod (3) out of lock (4).
Release screws (1) and turn lock (2) to right.
Turn lock (1) to right until guide (2) is located in metal cutout (3) and then
remove towards bottom.
Installation:
Replacement only:
Pull off rubber grommet (1).
51 24 100 Removing and installing/replacing rear lid lock (upper section)
Remove panel for rear lid.
Convertible only:
Remove additional brake light.
Unclip plug connection (1) in direction of arrow from cover fastener and
disconnect.
Loosen screws (2).
Unclip cover fastener (3) in direction of arrow.
Installation:
Ensure retaining lugs (1) are correctly seated.
Place Bowden cable (2) in mount (3).
Feed plug (4) as illustrated through opening.
Ensure catches (5) are correctly seated.

Release screws (2) and feed out upper section of rear lid lock (3).
Installation:
Use thread-tapping screws.
Remove lock (1).

Lever out actuating rod (2) and remove upper section of rear lid lock (3).
Installation:
51 24 130 Removing and installing/replacing striker for rear lid lock
Lever out trims (1).

Raise trim (1) slightly and remove rear lid lock (2) (rear lid lock lower
section).Installation:
Adjust rear lid lock.
Important!
Striker and rear lid lock must not be greased.
51 24 ... Removing and installing/replacing trim on shaft bearing for rear
window wiper
Lever out covers (1).Installation:

Catches (2) of covers (1) must not be damaged.
Release nuts (1) and remove trim (2).

51 31 ... General procedure for the disassembly and installation of
bonded window glass
1 General information
Follow general instructions on window bonding.
Materials needed for window bonding.
The vehicle can be towed away or driven without a windscreen, rear window and side window.
When carrying out disassembly/installation work and during the hardening time, the vehicle must be standing
on its wheels on a level surface.
The windscreen, rear window and side windows are glued to the body. This bonding will increase the torsional
rigidity of the vehicle. To obtain perfect bonding, comply with the installation procedure described in the
following.
2 Disassembly
2.1 Disassembly in general
The following dismantling methods are applied, according to the version:
Oscillating knife (not permissible for vehicles with window bonding on carbon body components)
Cutting wire with wire pull handles
"Spider" window glass removal system (unsuitable for severely damaged window glass)
Note:
When cutting out the window glass with wire pull handles, there is a risk of damage to the window glass
if the wire is pulled over the window edge.
Unless otherwise described, only use this method when replacing the window glass.
Follow the vehicle-specific repair instructions!

2.2 Disassembly of damaged window glass
The disassembly method described in the REP may be unsuitable depending on the degree of damage.
e.g. suction cups cannot be attached to window glass around cracks
Damaged window glass may damage and tear the nylon string
Attention! Risk of damage!
Use one of the other disassembly methods at your own discretion in the event of severely damaged window
glass.
Make sure adjacent components are adequately protected.
3 Installation
3.1 Preparation
Position the windscreen or rear window on a universal work top or secure the components on a tool trolley
using suction lifters.
Attach two suction lifters to the outsides of the window glass in the event of storage on a universal work top.
According to its size, fix side and door window glass onto the tool trolley using suction lifters or special tool
51 3 220 and set down on a suitable support.
Always keep the suction faces of the window glass suction lifters dry and clean.
Note:
If accessibility is restricted, insert the window glass on a trial basis.
Bond two yellow plastic adhesive tapes (1) approx. 400 mm in
length to the roof.
(A) = 250 mm
Only the yellow plastic adhesive tape may be used to fix the
window glass.
The glass will slip down if other adhesive tapes are used.
Window glass slippage will result in leaks and wind noises.
After completing the paint work, the paint must be fully hardened
before the plastic adhesive tapes are applied.
3.2 Pre-treatment of bonding surfaces

Protect the vehicle interior against contamination, cover the Head‐Up Display.
Clean window glass and body aperture (with residual adhesive bead) with cleaning agent R2
Attention! Do not use Sika remover 208 for cleaning in the adhesive area.
Observe an air drying time of at least 5 minutes (at least 15 minutes when applied to residual adhesive
bead)
Remove residual adhesive bead from body and window glass (see point 3.3)
Touch up paintwork damage to body aperture with BMW multibase filler (except for carbon body
components)
Pretreatment on new body component (no residual adhesive beads present):
Surface Pretreatment
Panel painted Wipe cleaning agent R1 dry with a paper towel or observe the air drying
time of at least 1 minute
Carbon Only cleaning agent R2
Carbon painted (e.g. roof outer Wipe cleaning agent R1 dry with a paper towel or observe the air drying
skin M3) time of at least 1 minute
Plastic (e.g. I01 A-pillar) Cleaning agent R2 and ScotchBrite Multiflex abrasive pad
3.3 Remove adhesive residue from the body and window glass
Do not remove residual adhesive bead (1) until shortly before

bonding.
Use the pitchweld scraper to remove the residual adhesive
bead (1) from the body aperture and window glass (3).
Position the pinchweld scraper (2) as shown and remove the
residual adhesive bead (1) up to a thickness of approx. 0.5 mm.
Attention!
Carbon body components are not to have scratches with a
depth greater than 0.2 mm.
Note, comply with life module check!
3.4 Installation of spacer (spacer buffer / dual-lock tapes)

Completely remove all residue of existing spacers before bonding new adhesive spacers.
The exact position of the spacers must be retained (see vehicle-specific repair instructions).
Incorrectly fitted spacers will result in:
Window glass breakage due to tension
leakage (if the spacer is in the adhesive area)
Wind noises
3.5 Add-on part
Depending on the version, attach sealing, expanding foam tape, rain sensor, etc.
Observe Overview of additional work with rain sensor when working with versions including the rain sensor!
3.6 Pre-treatment of new window glass
Apply a thin coat of glass activator (yellow stick); a final wipe is not necessary.
Observe an air drying time of at least 2 minutes
The glass activator is used for adhesion between glass or ceramic glass and the adhesive. Therefore, a thin,
homogeneous and continuous line of glass activator must be applied. If the window glass is to be reused with
a cut-back adhesive bead, glass activator is not needed.
It must be guaranteed that a 1 to 2 mm wide line of glass activator is located on the ceramic glass next to the
squeezed adhesive bead.
The adhesive bead may become up to 15 mm wide in compressed condition. The width of the glass activator
is therefore normally a minimum of 17 mm for windscreens and rear windows and a minimum of 9 mm for side
windows.
The glass activator may not be applied in the field of view or the point grid. Fresh glass activator in the field of
view must immediately be wiped off with cleaning agent R2 because hardened glass activator will leave a haze
behind.
3.7 Version with inspection glass for vehicle identification number in windscreen
Foam tape (2) must be installed to protect the vehicle

identification number (1) against tampering. If necessary, install
foam tape 07 14 7 222 909.
Close off the inspection glass on the windscreen (bottom left)
with Sika bonding base VP 206.
Except for:
All US/GB models
All models with a black dashboard cover, which means that
the vehicle colour cannot be seen through the inspection
glass
3.8 Nozzle preparation
Use the standard nozzle C for windscreens, rear windows, and

body-specific fixed side window glass.
A 8 ±1 mm
B 12 ±1 mm
Prepare plastic nozzle for fixed door window glass.
A 8 ±1 mm
B 15 ±1 mm
Deviations are described in the vehicle-specific repair instructions.

Black ceramic glass impermeable to UV light is located on the peripheral zone of the inside of the window to
protect the adhesive bead.
Ceramic glass must not be damaged.
3.9 Apply adhesive
Adhesive is applied to the window glass using a cartridge gun.
Glue cartridge must be vertical to window glass.
The almost vertical part of the adhesive bead must be facing the outer window glass edge.
On window glass with guidelines, the adhesive bead must be applied centrally between the guidelines.
On window glass without guidelines, the position of the adhesive bead is specified in the vehicle-specific repair
instructions.
Coat bead joint.
Effect of differing adhesive quantities:
Too little adhesive: Too much adhesive:
Window glass rests too low in Window glass rests too high in body aperture
body aperture Wind noise may occur
Insufficient squeezing of adhesive Strains/tensions may occur (window glass breakage)
bead (leaking)
Dirt contamination of add-on parts by emerging adhesive
Adhesive on uninsulated strainer pressure lines of aerial(s)
(interference of reception)
Note on bonding of windscreen:

The adhesive amount specified in the vehicle-specific repair instructions is sufficient if the specified adhesive
bead size is maintained.
If too much adhesive is applied due to application-related variations (manual application), the specified
adhesive amount may not be sufficient. To avoid interrupting adhesive application for longer than the permitted
period, have another glue cartridge ready.
Attention!
Once the adhesive bead has been applied, the window glass must be installed within 7 minutes
(depending on air humidity, temperature).
After 7 minutes the adhesive bead forms a skin which can no longer guarantee a perfect bond.
3.10 Mounting the window glass

To prevent a pressure build-up in the passenger compartment when the doors are closed:
Open a side window
Mount window glass (1) with suction lifter (51 3 010).

3.11 Adjusting the window glass
To avoid wind noise, the front and rear windows (1) must be
lower than the roof outer skin (2).
Check ride height of the windscreen or rear window using
Dimension (A) of window glass offset, refer to vehicle-specific
repair instructions.
X = measurement stages 1 ... 4 mm
3.12 Fixing the window glass
Fix the window glass with yellow plastic adhesive tapes (2).
Immediately remove dirt contamination with adhesive residue
using Sika remover 208. Do not press out the window glass
again.
3.13 Label
Depending on version, apply label.
51 31 ... Materials for bonding window
51 3 220
1 Tools
Type Type Order/part number

Electric special cutter SuperCut FSC 1.6Q 81 43 2 296 987
Knife set 81 43 9 428 596
Contains:
Knife (U-shape) 24 / 36 / 45 mm
Knife (L shape) 25,4 mm
Knife (straight with stop roller) 16 to 43 mm (adjustable)
14 mm (fixed)
”Roll Out 2000” Wire cutting system 81 62 0 301 768
"Spider" Cutting system with nylon string 81 43 2 357 248
Wire pull handles 81 43 2 326 501
Cartridge gun 81 49 2 213 059
Pinchweld scraper set 81 62 0 410 436
Siphon 81 64 2 184 377
Single suction cup Special tool 51 3 220
Universal work table 81 49 0 151 675
2 Consumables:
Naming of Electronic Parts Designation, repair BMW part number

Catalogue instructions /addition
Window glass repair kit, Small repair kit 83 19 2 289 285
cold, 1 hour
83 19 2 289 180 (US)
83 19 2 180 001 (China)
Window glass repair kit, Large repair kit 83 19 2 360 680 (not available for
cold, 1 hour the US/China)
Like small repair kit,
plus 1x window glass adhesive 300 ml
Cutting wire for glass repair Cutting wire, square 83 19 2 150 267
Nylon string Nylon string 81 43 2 344 272
Multi-base filler BMW multibase filler
Cleaning agent R1 Cleaning agent R1 83 19 2 211 217
Cleaning agent R2 Cleaning agent R2 83 19 0 417 324
Adhesive tape Plastic adhesive tape, yellow 83 19 9 410 979
Adhesive cleaner 208 Sika remover 208 83 19 9 407 780
Aktivator 205 Sika Activator 205 83 19 0 030 155
(e.g. for rubber frame on windscreen)
Bonding base VP 206 Sika bonding base VP 206 83 19 9 407 777
(e.g. for inspection glass for vehicle
identification number)
Storage of all consumables

Dry at 15 ° - 25 °C.
51 31 ... Notes on window bonding
These notes are not applicable for side window bonding (door ”centre”) on E38/L7.
General procedure for disassembly/installation of bonded window glass.
Version with Head‐Up Display (HUD):
Marking for HUD must be present on the windscreen
Adhesive quantities:
Approx. 1 1/4 glue cartridges are required to bond the windscreen on the following vehicles:
7 Series
5 Series from E60
X5
X3
Version with GPS navigation system 1 (up to 09/1997):
After installation of rear window:
Recalibrate magnetic field probe
Refer to functional description in ISID (Integrated Service Information Display)
51 31 ... Notes on window bonding repair kit
Part number Part Part
number (US) number (China)
Small repair kit 83 19 2 289 285 83 19 2 289 180 83 19 2 180 001
- Window glass adhesive 300 ml 83 19 2 289 286 83 19 2 289 181 83 19 2 180 002
- Glass activator 83 19 0 444 142
- C nozzle 83 19 2 155 589
- Plastic nozzle and paper tissue
Large repair kit 83 19 2 360 680 Not available Not available
(Contains an additional window glass adhesive
300 ml)
Important!
Before working with the consumables, note the following information.
Processing instructions on the packaging
1 Storage and processing of all consumables

Dry at 15 ° - 25 °C.
2 Expiry date of adhesive:
Repair kit and glue cartridges are marked with a date (expiry).
Date (1) refers to the calendar week and year (KW/JJJJ).
The adhesive cannot be used after this date (1).
3 Hardening of adhesive:
The adhesive hardens by reacting with air humidity at room temperature.
Important!
Once the adhesive bead has been applied, the window glass must be installed within 7 minutes
(depending on air humidity, temperature).
After 7 minutes the adhesive bead forms a skin which can no longer guarantee a perfect bond.
At ambient temperatures above 23 °C and 50 % relative air humidity (hot countries), the adhesive open time is
shortened to approx. 5 minutes (skin formation time).
A relative air humidity of < 30% significantly slows hardening.
The adhesive hardening process is interrupted completely at ambient temperatures below 5 °C. In this event,
there will be no increase in the strength of the bonded connection.
3.1 Minimum hardening time:
Minimum hardening time is reached beginning at 22 °C and 38 % relative air humidity.
1 hour, vehicles without front passenger airbag (after which vehicle can be moved)
2 hours, vehicles with front passenger airbag in countries without mandatory seat belt usage
Note:
In vehicles with front passenger airbag in countries without mandatory seat belt usage:
The vehicle can be transferred to the customer after a 1-hour hardening time with the following
warning:
Once the windscreen glass has been bonded, all occupants must travel with their seat belts
attached for 1 hour.
Important!
If the minimum hardening time is not adhered to, an accident can cause the passenger together with
the windscreen to fall out of the vehicle after the front passenger airbag deploys.
During the minimum hardening time of 1 hour, the vehicle must not be subjected to load on one side such as
e.g.:
one wheel on kerb
vehicle hoist
etc.
Manoeuvring inside garage/workshop:
only permitted on level ground
do not under any circumstances drive over approach ramps, e.g. into multi-storey car parks
Do not remove adhesive tapes until after hardening time.
If the minimum hardening time of 1 hour is undercut, leaks and wind noises may occur at the window glass.
4 Disposal of adhesive:
Non-hardened adhesive, glue cartridge and mixtures of adhesive and solvents and the like must be disposed
of as hazardous waste.
The adhesive is disposed of in paper sacks so that it can react with moisture.
5 Glass activator:
Warning!
Wear cut resistant gloves when breaking the glass ampule.
Prepare glass activator for processing by shaking and snapping (breaking glass ampoule).
Apply glass activator by pressing gently. There is no need for final wiping. Air drying time approx. 2 minutes.
6 Expiry date of glass activator:
Repair kit and glass activator are marked with a date (best before date).
The glass activator may only be used up to this date (if not already opened previously).
After opening, keep only for one week even if the expiry date has not yet been reached.
7 Disposal of glass activator:
Glass activator must not be disposed of as part of household waste.
Glass activator must be disposed of as hazardous waste.
61 35 ... Overview, rain sensor (additional work when replacing the
windscreen / sensor replacement)
1-Series: E8x
3-Series: E9x
5-Series: E6x
6-Series: E6x
X1: E84
Z4: E89
Sensor type/ With windscreen When replacing When Connecting the

replacement replacing diagnosis system
Sensor shape the sensor/
replacement sensor the sensor/ required
Programming/encoding
required Initialisation
necessary required
Condensation Yes No No No
sensor
square
30 x 20 mm
5-Series: E6x
6-Series: E6x
7-Series: E6x
Sensor type/ With windscreen When replacing When replacing When Connecting
replacement replacing the
Sensor shape the sensor substitute visuals diagnosis
replacement the system
sensor Programming/encoding Programming/encoding sensor/
required
required necessary necessary substitute
visuals
Initialisation
required
all types No Yes - Yes Yes
square
60 x 40 mm
RLS No - No Yes Yes
approximately (new substitute
ø 50 mm visuals required,
refer to Electronic
Parts Catalogue)
X5: E70
X6: E7x
Sensor type/ With When replacing When replacing When Connecting
windscreen replacing the
Sensor shape replacement the sensor substitute visuals diagnosis
the system
replacement Programming/encoding Programming/encoding sensor/
sensor required
visuals
Initialisation
required
RLPSS (Rain, Yes Yes - Yes Yes

light and
precipitation solar
sensor)
(Designation is
located on the
back of the
sensor)
approximately ø
50 mm
RLS (vehicle with No - No Yes Yes
no HUD)
(new
(Designation is substitute
located on the visuals
back of the required,
sensor)
refer to
approximately ø Electronic
50 mm Parts
Catalogue)
RLSS (vehicle Yes Yes - Yes Yes
with HUD)
(Designation is
located on the
back of the
sensor)
approximately ø
50 mm
1-Series: E8x
3-Series: E9x
X1: E84
X3: E83
Z4: E89
Sensor type/ With windscreen When replacing the When replacing Connecting the
replacement sensor the sensor diagnosis system
Sensor
shape replacement sensor Programming/encoding Initialisation required
required required
necessary
all types No Yes Yes Yes
square
60 x 40 mm
5-Series: F1x
5 Series GT: F07
6-Series: F06, F1x
7-Series: F0x
X3: F25
X4: F26
Sensor type/ With windscreen When replacing the When replacing When Connecting
replacement sensor replacing the
Sensor substitute visuals diagnosis
shape replacement Programming/encoding the system
sensor required Programming/encoding sensor/
necessary required
necessary substitute
visuals
Initialisation
required
all types No No - Yes Yes
approximately
ø 35 mm
all types Yes Yes - Yes Yes
approximately
ø 50 mm
Only for F25 : No - No Yes Yes
RLS (new substitute
visuals required,
approximately
ø 50 mm refer to Electronic
Parts Catalogue)
X5: F15, F85

X6: F16, F86
Sensor shape
replacement sensor Programming/encoding Initialisation required
required required
necessary
all types No No No No
approximately ø
35 mm
1-Series: F2x
2-Series: F2x
3-Series: F3x, F8x
3 Series GT: F34
4-Series: F3x, F8x
Sensor type/ With windscreen When replacing the When Connecting the
replacement sensor replacing the diagnosis
Sensor shape sensor system
replacement Programming/encoding
sensor required Initialisation required
necessary required
all up to 03/2014 except SBS No No Yes Yes
(01)
(Designation is located on the
back of the sensor)
approximately ø 35 mm
SBS (01) No No No No
back of the sensor)
All as from 03/2014 No No No No
2-Series: F4x
Sensor With windscreen When replacing the When replacing the Connecting the
type/ replacement sensor sensor diagnosis system
Sensor replacement sensor Programming/encoding Initialisation required
shape required required
necessary
BMW i:
Sensor shape
required required
necessary
approximately ø
35 mm
BMW from G series
necessary
MINI (all):
Sensor shape
required required
necessary
square
60 x 40 mm
approximately ø
35 mm
Rolls-Royce:
RR1
RR2
RR3
RR4
RR5
RR6
Sensor shape
required required
necessary
square
60 x 40 mm
all types No No Yes Yes
approximately ø
35 mm
all types Yes Yes Yes Yes
approximately ø
50 mm
Rolls-Royce:
RR11
RR12
Sensor shape
required required
necessary
approximately ø
35 mm
51 31 ... Remove windscreen with "Roll Out 2000"

2 150 267
"Roll Out 2000" has been replaced by the "Spider" removal system."Roll
Out 2000" may still be used. The "Spider" removal system is
recommended for removing window glass.
"Roll Out 2000" window glass removal system
1 Wire starter 8 Extension (short)

2 Parabolic tool 9 Extension (long)
3 Plastic washer 10 Reversible ratchet
4 Wire cutting roller 11 Plastic wedge
5 Suction cup lifters 12 Guide needles
6 Protective gloves 13 Suction cup lifter with double spool
7 Safety goggles
Note:
Both paint and ergonomic and health-endangering damage is minimised
with the "Roll Out 2000" system.
Sourcing reference:
See Aftersales Assistance Portal (ASAP) - Service/Technical -
Workshop Equipment (Start BMW) - Shop Workshop Equipment or at
www.bmwgroup.com
Warning!
Follow safety instructions for working on vehicles with airbag
systems (risk of injury).
Important!
Take care when handling sharp-edged tools and cutting wire (risk of
damage to head airbag and window glass).
Important!
Always keep both suction cups dry and clean to ensure their
optimum adhesion on the windscreen.
Suction cup may not be applied at the damaged point (crack in
window glass).
Lubricate spool if lock rattling becomes too loud.
Always wear safety goggles and protective gloves for your own
safety.
Mounting suction cup lifters on windscreen or rear window:
Secure position of lifting jacks as shown (view from outside):

1. Suction cup lifter with double spool
2. Suction cup lifter with single spool (as deflecting point)
3. Window
4. Cutting wire
Note:
Optimum cutting is guaranteed when the cutting wire is at an acute angle to the adhesive bead. There is a risk of the cutting
wire breaking if the angle is too obtuse.
The suction cup lifter (2) is used as the deflection point to achieve the corresponding angle.
Depending on the window glass version and the effort applied during cutting, it may be necessary to change the deflection
point during cutting.
The suction cups without a spool can even be used as the deflection point.
Preparatory work:
Cut off required cutting wire length:
Length approximately = 6 x window glass diagonal
The cutting wire loops must lie on top of each other in area (B).
They must not get caught up in each other. (Otherwise no possibility of cutting the adhesive bead/wire will break.)
Overlapping of cutting wire loops approx. 10 cm.
Distance from right window edge approx. 30 cm.
Pulling cutting wire into vehicle:

Grip wire with pliers
(If accessibility is bad, stick wire with wire starter 2 150 267 through
adhesive bead.)
Wire end (1) must be bent towards window glass.
Heat wire end (1) and use it to pierce adhesive bead (2).
Pull the wire approximately 1.5 m into the passenger compartment
Using wire starter:

Bend wire end approx. 10 mm and insert in notched tip.
Pierce wire starter with uniform pressure through adhesive bead, wire
end (bent part) must be positioned on window glass.
Laying cutting wire around window glass:
Starting from pull-in point, lay wire eyelet created on the outside
around the window glass
Pull excess wire into passenger compartment
Important!
Make sure the cutting wire is located at all four corner points below
the window glass.
Check that the cutting wire is not caught on clamps or body.
Secure window glass on outside with adhesive tape against sliding.
Note:
Window glass (1) with installed seals (3) or moulded-on surrounds:
Moisten cutting wire (4) and seals (3) on window glass (1) with water
Insert cutting wire (4) in bend (without kinking) between
window glass(1) and body aperture (2)
Protect the passenger compartment:

To avoid damage and possible dirt contamination, protect A-pillars,
roof and dashboard trim panel (3) by means of plastic washer (1)
Always carry plastic washer (1) between respective wire (2) being
tightened and trim panels
Attaching wire in hoisting winch with double coil:

Bend over cutting wire end (1) approximately 10 mm and insert into
slot of spool (2)
Repeat process with other end of wire (1) and second spool (2)
Wind cutting wire (1) onto spools by hand until cutting wire (1) is
under slight tension
Starting the dismantling: Note:
Spools can only be rotated in one direction.
Make sure the wire is always situated in the guide channel of the
suction cup lifter (1)
Fit reversible ratchet onto top spool shaft (2) and tighten wire
Start by cutting lower adhesive bead
At the end of the cutting process, the two wire loops join up at the
lifting winch (1)
Remove "Roll Out 2000"
Remove window glass
51 31 000 Removing and installing front windscreen

00 9 322
51 3 010
51 3 130
Caution!
The "Instructions for window cementing" serve as the basis for
these repair instructions and must be followed without fail.
Cover front side panels with protective covers.
Remove cowl panel cover.

Remove interior rearview mirror.
Remove both sun visors and counter support.
Remove both panels for front roof pillar.
Remove rubber frame for windshield.
Remove side cover (1) on left/right.
Tape off body at roof edge with fabric adhesive tape (e.g. Tesa).
Cover cowl panel bottom edge with tape.
Attach adhesive to edges on front side panels.
Cover body at left and right A-pillars with adhesive tape.
1. windshield
2. Glue bead
3. Body opening
4. Fabric adhesive tape
Fit 36 mm blade (sourcing reference: BMW Parts Service) to the tool.
Note:
Resharpen knife with machine running.
Carefully insert knife between body and windshield.

Guide handle of knife parallel to windshield.
Cut through glue bead all around and as close as possible to windscreen
glass.
Lift out windshield using special tool 51 3 010 .
Immediately before installing windshield:

Remove residual adhesive in body cutout and if necessary on windshield
down to a thickness of approx.0.5 mm.
To avoid damage to paintwork in body cutout, carefully cut off residual
adhesive with a heavy-duty scalpel (1).
Caution!
Clean freshly cut residual bead with spirit only,
do not under any circumstances use Sika bonding agent 205/5.
Caution!
First, completely remove remnants of old spacer buffers (3)
(windshield breakage).
Stick on two new spacer buffers (3) at distance (A) from center of cowl
panel.
A 260 mm
1 windshield
2 Glue bead
Summary for cementing of windshield (E46):

1 Glue bead D1 20 ± 1 mm (width of primer trace)
2 Ceramic layer D2 15 ± 1 mm (width of primer trace)
3 Primer coat E1 3 ± 1 mm (distance from 3 to 6)
4 Application point of glue bead E2 0 mm (distance from 3 to 5)
5 Rubber frame, top/side F 400 mm (distance from 4 to 6)
6 Window edge R1 approx. 14 mm (radius of 3)
7 Sight glass for US chassis number R 2 approx. 14 ... 19 mm (radius of 3)
A 7 ± 1 mm (width of adhesive bead) R3 approx. 20 mm (radius of 1)
B 11 -2 mm (height of adhesive bead) R4 approx. 20 ... 25 mm (radius of 1)
C1 8 ± 1 mm (distance from 1 to 6)
C2 2 ± 1 mm (distance from 1 to 5)
Attach special tool 51 3 010 to tool trolley. Moisten suction faces and firmly grip windshield.
If re-using old windshield, remove residual adhesive down to thickness of 0.5 mm.
Fit rubber frame (5), noting center marking on frame and windshield.
Almost vertical part (B) of adhesive bead (1) must face window edge (6).
Spread adhesive bead (4) with special tool 00 9 322 .
Note:
Adhesive area for plastic adhesive tapes (1) must be free of grease and
dust.
Attach two yellow plastic adhesive tapes (1) (Tesa)

to roof at a distance (A) from outer corners.
Length: 400 mm
Width: 50 mm
(A) 250 mm
Using special tool 51 3 010,
first position windshield at top,
align evenly at sides,
then install and press down at bottom. Press windshield upwards until
seal evenly touches roof.
Secure windshield in this position at top with two yellow plastic adhesive
tapes (Tesa).
Convertible only:
Radius of rubber frame (1) of windshield may stick out and must therefore
be pretensioned with special tool 51 3 130 .
From the set, only the HR foam blocks (2) with the dimensions 40 x 30 x
70 mm (W x H x D) are used.
Pretension windshield with plastic adhesive tape (3) (Tesa) until it is
correctly positioned at top.
Note:
Do not stick plastic adhesive tape (3) over A-pillar finisher.
51 31 200 Removing and installing rear window
Note:
When gluing the rear window, glues for cold and hot processing are
permitted.
Cover rear side panels with protective covers.
Removing and installing both trim pieces for rear roof pillar,
refer to 51 43 251.
Cold processing:
Comply with instructions on gluing windows,
refer to 51 31 ...
Warm processing:
Open rear end of aluminum membrane in cartridge before installing in
cartridge oven.
Heat glue cartridges to 80 °C for one hour in oven (sourcing reference:
BMW Parts Service).
refer to 51 31 ...
Disconnect right plug connection (1) (wave trap).
Disconnect plug connection (1), release nut (2) and secure leads to rear
window with adhesive tape.
Raise trunk lid by about 65 cm and hold in this position (e.g. attach
welding wire with two hooks between lock and lockpin).
Remove seals (1).
Mask edges of trunk lid and all round body with fabric adhesive tape (e.g.
Tesa).
1. Rear window
2. Glue bead
3. Body opening
4. Fabric adhesive tape
Fit knife (24 mm blade length, sourcing reference: BMW Parts Service) to
the tool.Note:
If necessary, resharpen knife with machine running.
Carefully insert knife between body and top center of rear window.
Guide web of knife parallel to rear window.
Caution!
When reusing the rear window:
Avoid damaging lines for rear window heating/antenna.
When cutting through the glue bead beside the trunk lid, it must be
opened for a short period by a 2nd person (risk of damage).
Cut through glue bead all around as close as possible to the rear window
glass.
1. Body opening
2. Glue bead
3. Knife
4. Rear window
Lift out rear window using special tool 51 3 010.
Cut off old glue in body opening but for a thickness of approx. 0.5 mm.
Cut off old glue carefully with an universal knife (sharp as a razor blade)
to avoid damaging the paint finish in body opening.
Pull off adhesive tapes all round.
Caution!
To provide long-term corrosion inhibition, damage to paintwork
(scratches and large areas of damage) should always be touched
up,
refer to 51 31 ...
When reusing the rear window:

Remove glue residue on windshield
with a scalpel (1) for heavy-duty applications
to approx. 0.5 mm.
Fit seal (1) at top in center of rear window and press downwards.Note:
Sealing strip (1) and rear window are marked in center (2).
Secure cable (1) (rear window heating/antenna) with adhesive tape.

Treat rear window around glued area (A) with materials approved by
BMW (repair kit, sourcing reference: BMW Parts Service),
refer to 51 31 ...
Note:
Note ventilation time!
Distance (A) from seal.

(A) = 15-2 mm (top/side)
(A) = 20-2 mm (bottom)
Caution!
The basic filler must have hardened!
Mask headlining on roof connection with paintwork masking tape.
Treat body in glued area with materials approved by BMW (repair kit,
sourcing reference: BMW Parts Service),
refer to 51 31 ...
Note:
Caution!
Before setting new spacer buffers,
remove remnants of old spacer buffers completely (broken rear
window).
Fit two spacer buffers at a distance (200 mm) from center of cowl
panel.
Cut nozzle to size.
(A) 7 mm
(B) 12+1 mm
Note:
To apply uniform glue bead, use cartridge pistol, operated with
compressed air or electric power (refer to BMW Parts Service).
Note expiry date of glue!
If applicable, produce a sample bead before gluing.

Cartridge must be arranged vertically against rear window.
Caution!
Version with rear window antenna:
No glue must come into contact with the connection contacts of the
rear window heating/antenna.
Shape of glue bead:

(A) 7 mm
(B) 12+1 mm
Caution!
Apply glue bead quickly and insert window. Skin formation time of
glue, maximum 10 minutes.
Maintain distance (A), (B) and (C) between glue bead and seal.
(A) 2 mm
(B) 2 mm
(C) 8 mm
Note:
Adhesive area for plastic adhesive tapes must be free of grease
and dust.
Attach two yellow plastic adhesive tapes (Tesa)

to roof at a distance (250 mm) from outer corners.
Length: 400 mm
Width: 50 mm
Install rear window carefully using special tool 51 3 010. The gasket must
make uniform contact all round (center). Press rear window upwards until
gasket is at uniform distance from roof all round.
Secure rear window in this position at top with two yellow plastic
adhesive tapes (Tesa).
Length: 400 mm
Width: 50 mm
Distance from outer corners approx. 100 mm.
Caution!
Remove dirt from residual glue with Sika-Entferner 208 (sourcing
reference: BMW Parts Service) before glue is hard. Do not press
out rear window glass again for this purpose. Hardened glue can
only be removed by machine.
Assemble car.
After the hardening time, remove adhesive tapes.
Note:
Leaks are localized by spraying under the sealing lips or by using an
ultrasonic leak tester (sourcing reference: BMW Parts Service) and
are sealed using an appropriate nozzle.
51 31 021 Removing and installing/replacing rubber frame for windshield
(top/side)
Caution!
Rubber frame is reinforced with an aluminum strip.
Do not damage windshield when removing rubber frame.
Carefully turn and remove rubber frame (1).
Installation:
Cut tear-off lip of rubber frame.
To facilitate installation, apply soapy water to rubber frame and body

cutout.
51 31 ... Removing windows with a "Spider"
Windscreen removal system "Spider"
1 "Spider" separation device 6 Line threader

2 Bit holder 7 Line routing tool
3 Operating instructions 8 Suction anchor
4 Dashboard protection 9 Cord for separating adhesive strips
5 Angular transmission
Accessories required for operation (not included):
Cordless screwdriver/drill with at least a 10.8 V Li-ion battery or a 18 V Ni-Cd battery and variable speed.
Note: Always use a low gear setting.
Note:
Damage as well as ergonomic and health-endangering damage are minimised with the "Spider" disassembly
system.
Sourcing reference:
See Aftersales Assistance Portal (ASAP) - Service/Technical - Workshop Equipment (Start BMW) - Shop
Workshop Equipment or at www.bmwgroup.com
Warning!
Follow safety instructions for working on vehicles with airbag systems (risk of injury).
Important!
Handle sharp-edged tools with care (risk of damage to the head airbag and the window glass).
Important!
Always keep both suction cups dry and clean to ensure their optimum adhesion on the windscreen.
Suction cup may not be applied at the damaged point (crack in window glass).
The bearing bushes of the shaft (spindle) must always be lubricated.
Always wear safety goggles and protective gloves for your own safety.
The procedure for disassembly of the windscreen is described below as an example.

Deviations in the work procedure can be found in the vehicle-specific repair instructions.
General
A cord approx. 6.8 m long is used to cut through the adhesive bead.
The cord length to be used is identified by a short red mark (A) approx.
5 cm.
The part of the cord laid outside around the window glass (approx. 5 m) is
identified with a long red mark (B) (approx. 18 cm).
The marks are applied so that the cord has to be pulled from the inside to
the outside.
Preparation
A. Pierce cord from the roller (1) or separation device (2) with cord threader (3) through the adhesive bead from the
inside, protect the area from the inside as required.
B. Pull out cord up to the first red mark (approx. 18 cm long).
C. Lay cord around the window glass, use pulling aid (4) if required.
D. Secure suction anchor (5) outside on window glass, secure cord to suction anchor (5).
If required, unwind cord from roller (1) up to the second red mark (approx. 5 cm long) and cut off.
Make sure the cord lies below the window glass at all four corners.
Check that the cord is not caught on clamps or body.
Secure window glass on outside with adhesive tape against sliding.
Feeding in the cord on the separation device
Normally, the adhesive bead is cut through anticlockwise seen from the passenger compartment.
This means the cord must be fed into the separation device as shown in graphic A.
When accessibility is not optimal, the opposite cutting direction may be required (comply with vehicle-specific repair
instructions).
This means the cord must be fed into the separation device as shown in graphic B.
Feed cord into coil and wind it on, at the same time trapping the end of the cord.
When winding the cord, the correct direction of rotation on the separation device must be observed.
Cutting out procedure

Optimum cutting is guaranteed when the cord is at an acute angle to the adhesive bead. There is a risk of the cord
ripping if the angle is too obtuse.
The separation device must be positioned correspondingly to achieve the appropriate angle.
A. Fix separation device (1) on window glass at bottom right.

B. Depending on accessibility, attach bit holder (2) or angle gear (3) to cordless screwdriver (4).
C. Place cordless screwdriver (4) on separation device (1) and start winding cord, observe direction of rotation on
separation device.
If required, over trim panel components with plastic protection.
Guide cord with plastic protection around sharp-edged positions.
Cut through adhesive bead up to bottom area of A-pillar.
Turn back cordless screwdriver (4) approx. 2 rotations and remove.
Cutting out procedure

A. Discharge vacuum on windscreen removal tool (1) by pressing the tab, remove windscreen removal tool (1) from
window glass.
B. Reset removal tool (1) at illustrated and wind up cord up to the position of windscreen removal tool (1).
C./D. Repeat further resetting, work sequence as given at B.
Additional resetting may be required for very curved window glass.
It is possible to reuse the cord. When a cord is used many times the risk of ripping increases.
Dirt contamination must be avoided when a cord is reused.
51 31 ... Removing windows with an oscillating knife
Warning!
Follow safety instructions for working on vehicles with airbag
systems (risk of injury).
Important!
Handle sharp-edged tools with care (risk of damage to the head
airbag and the window glass).
Important!
Always wear safety goggles and protective gloves for your own
safety.
Cover the working area (side walls, roof-mounted aerial and if
necessary interior equipment) with protective covers.
Tape off body with fabric adhesive tape (e.g. Tesa) in areas where
the oscillating knife could damage the window glass or the paint.
Use suction cups (51 3 010) to lift out the window glass.
Always keep both suction cups dry and clean to ensure their optimum
adhesion on the windscreen.
Secure window glass against falling out.
Depending on the area of application, knife 1 or 2 is used.

(1) Straight knife with adjustable thrust roller
(2) U-shaped knife
Dimension (X) on the knife (1) can be adjusted individually, see vehicle-
specific repair instructions.
Note:
Sharpen knife blade before every use on a running machine with a
grinding stone (even with new knife blade).
Removing from the inside:
Guide knife carefully between body and window glass.
Run blade of knife parallel to glass.
Take care not to damage paintwork.
Cut through adhesive bead all the way around.
Pull window glass outwards to remove.
Removal from outside:

Guide knife carefully between body and window glass.
Run blade of knife parallel to glass.
Take care not to damage paintwork.
Cut through adhesive bead all the way around.
Pull window glass outwards to remove.
Cut through adhesive bead as closely as possible to window glass.

(1) Body opening
(2) Adhesive bead
(3) Knife
(4) Window
51 31 015 Repairing damage to windscreens caused by stone chips (clear
and tinted laminated safety glass)
Field of vision (no repairs acceptable):
A 50Â mm (gap between field of view / centre of vehicle)

B Up to end of wiper range, outside (field of view width)
C Restriction by wiper range (height of field of view)
Important!
Repairs must only be carried out outside of the field of vision (refer to sketch).
If the stone chip damage is outside the field of vision, refer to repair instruction.
51 31 221 Replacing rear window (rear window broken)

Removing and installing rear window,
refer to 51 31 200.
Remove all glass splinters, also from underneath seats.

Check seat belts:
Condition of seatbelt strap
Operation of retractor mechanism
- Check seat belt locking reel and
- seat belt buckle.
51 31 ... Window glass removal with wire pull handle

2 150 267
Warning!
Follow safety instructions for working on vehicles with airbag systems (risk of injury).
Always wear safety goggles and protective gloves for your own safety.
Attention!
Handle sharp-edged tools with care (risk of damage to the head airbag and the window glass).
Attention!
Protect inner and outer working area (body, trim panels, cables etc.) against damage.
Depending on the area of application, a separating cord can also be used as an alternative to wire.
Using the separating cord prevents any damage to the body.
Do not pull the separating cord over any sharp edges (risk of tearing)!
Used tool:
Wire pull handles
Dashboard protection
Wire starter (special tool 2 150 267 )
Use suction cups (51 3 010) to lift out the window glass.
Always keep both suction cups dry and clean to ensure their optimum
adhesion on the windscreen.
Secure window glass (if necessary with adhesive tape) against falling
out.
Pulling cutting wire into vehicle:
Grip wire with pliers
(If access is difficult: using wire starter 2 150 267 , feed wire through
adhesive bead.)
Wire end (1) must be bent towards window glass.
Heat wire end (1) and use it to pierce adhesive bead (2).
Pull approximately half of the wire into the passenger compartment
Note:
When using the separating cord, always pull it in using the wire
starter 2 150 267 .
Using wire starter:

Bend wire end approx. 10 mm and insert in notched tip.
Pierce wire starter with uniform pressure through adhesive bead, wire
end (bent part) must be positioned on window glass.
Attach wire pull handles:

Feed in cutting wire (1) in cutting handle (2) and clamping element (3) as
illustrated.
Move back cutting handle (2) over clamping element (3) and trap wire
end (4).
Danger of injury!
Wire end (4) must not protrude out of cutting handle (2).
Cutting handle (2) can be secured with suction cup (5) to the vehicle
window or body during each of the work operations. This prevents
damage to the paint.
Fit second wire pull handle to other wire end.
Perform repair work with the aid of a second person.

Cutting wire (4) must be guided in cutting direction at an acute as
possible angle (>45°) to adhesive bead (1).
Cut through adhesive bead (1) by pulling cutting handle (2) and at the
same time providing counter support with cutting handle (3).
Pull back cutting wire (4) with cutting handle (3) and make sure that
cutting wire (4) is always held under tension.
Cut through remaining adhesive bead in the same way.
51 32 154 Adjusting left or right front door window
Note:
To release or partially detach sound insulation, follow procedure in
”Removing and installing/replacing sound insulation on front left or
right door”,
refer to 51 48 ...
Partially detach sound insulation at rear and secure with adhesive tape
(1).Note:
Acoustic insulation as shown in illustration only serves as an
illustration: It is not identical to detached acoustic insulation.
Slacken nuts (1) and (2) (do not release).

Open door window glass fully with window lifter (3).
Tighten nuts (1) and (2).
Installation:
Tightening Torque,
51 32 160 Removing and installing/replacing cover (anti-trapping protection)
on door window frame, left or right, inside

refer to 51 41 000.
Unfasten clips (1).
Lever out cover (1) towards inside,

feed out from door brake (2) and
detach from retainer (3).
Disconnect plug connection (1) for anti-trapping protection.
Detach cover (1) from retainer (2) and remove rest.

Installation:
If necessary, remove retainers (1) from cover (2) and insert in front
door.
If necessary, replace foam (3).
51 32 170 Removing and installing/replacing door window glass, front left or
right

00 9 314
Note:
When removing the door lock (51 21 140), you only have to remove the
sound insulation in the rear area.
Remove sound insulation on front door.
When removing the power window lift (51 33 000), do not remove the
door window glass and the outer window cavity cover strip.
Only for removal and installation of door window glass:
If necessary, remove outer window cavity cover strip.
Open door window glass to distance (A).

A approx. 140 mm
Slacken screw (1).
Note:
When removing door lock (51 21 140),
release the door window glass at the rear only
and move fully towards top.

A approx. 140 mm
Caution!
Version with power windows:
If necessary, disconnect battery negative lead.
Slacken screw (1).

Note:
When removing the power window lift (51 33 000), do not remove the
door window glass (1).
If necessary, push door window glass (1) towards top and secure from
inside with special tool 00 9 314 (adjustment wedges).
Turn door window glass (1) and lift out towards rear/top.
Installation:
Each time the door window glass is removed or replaced, the holder (2)
must be replaced.
If necessary, fit new screws (1) and nuts (3) on door window glass (4).
Adjust door window glass.
51 32 420 Removing and installing/replacing finisher on front door window
frame, left or right
For removal and installation only, not for adjustment:

Remove cover (anti-trap protection) on door window frame.
Open door window.
Partially detach rubber window seal (1) at rear.
Loosen screws (1).

Remove finisher (2) and press approx. 3 mm towards rear.
Remove trim (1) towards top.

Installation:
If necessary, replace faulty plastic nuts (1).
Installation:
Check finisher (1) for damage, replace if necessary.
Installation:
To prevent wind noises.
Check gap with a 0.05 mm feeler gauge.
Slide feeler gauge between B-pillar finishers of front and rear doors.
When the finishers are correctly adjusted, it must be possible to feel a
slight suction resistance over the entire length of the finisher.
If the gap is too big, this may result in wind noises.
Installation:
If necessary, release screws (1).
Press finisher (2) towards rear and tighten down screws (1).
If gap is still too big,

adjust finisher on window frame of rear door.
51 32 211 Replacing front left or right rubber guide for left or right door
window
Remove mirror on front door.
Note:
Remove cover from door window frame completely.
Open complete door window glass completely.
Remove sound insulation (1).
Release rivet (1).

Remove complete rubber guide (2) from front door (3).
Installation:
Coat rubber guide (2) with water prior to installation.
Insert rubber guide at front/bottom in window guide channel.
Installation:
Sound insulation (1) must be fitted and must not be damaged.
51 33 000 Removing and installing electric window regulator in left or right
front door
Release door window glass but do not remove,

refer to 51 32 170.
Release nuts (1) and (2).

Feed out window lifter (3) towards inside/bottom and deposit at bottom in
door.
Note:
The work for ”Removing/replacing door lock (51 21 140)” ends here.
Unfasten cable clip (1).

Lift out clip (2).
Release nuts (1) and (2).

Feed out window lifter (4) with drive (3) towards inside/bottom and
deposit at bottom in door.
Installation:
Tightening Torque,
When removing, first feed out front part (1) of window lifter with drive (2).
Replacement only:
Unfasten clip (1).
Release screws (2) and remove drive (3).
51 34 160 Removing and installing/replacing cover (trapping protection) on
door window frame (rear door), inside left or right

refer to 51 42 000.
Lift out cover (1) from fixed door window.Note:

Do not tear off cover (1) in area (2).

Lift out and remove cover (2).
Installation:
Connection (1) of cover (2) must not be damaged.
Check function.
51 34 420 Removing and installing/replacing trim on window frame of rear
door (front), left or right
For removal and installation only, not for adjustment:

Remove window cavity cover strip on outside of rear door.
Open door window.
Partially pull off rubber seal (1) and rubber guide (2).
Loosen screws (1).

Detach trim (2) towards front/top.
Installation:
If necessary, replace faulty plastic nuts (1).
Installation:
Trim (1) must not be damaged.
Installation:
To prevent wind noises.
Check gap with a 0.05 mm feeler gauge.
Slide feeler gauge between B-pillar finishers of front and rear doors.
When the finishers are correctly adjusted, it must be possible to feel a
slight suction resistance over the entire length of the finisher.
If the gap is too big, this may result in wind noises.
Installation:
If necessary, release screws (1).
Press finisher (2) towards front and tighten down screws (1).
If gap is still too big,

adjust finisher on window frame of front door.
51 34 ... Removing and installing/replacing trim on window frame of rear door
(rear), left or right

Remove cover on door window frame (rear door).
Remove rubber guide (1) from trim (2).
Grip trim firmly and release screws (1).
Push trim (1) downwards from rubber guide (2) and remove towards top.
Installation:
Threads (1) of trim (2) must not be damaged.
Installation:
Foam section (1) must be fitted.
51 34 000 Removing and installing/replacing window crank, rear left or right
Remove plate (1).
Installation:
Guide (1) and catch (2) if finisher (3) must not be damaged.
If necessary, replace faulty finisher (3).
Unscrew bolt (1).

Remove window crank (2) and rosette (3).
Installation:
Fit window crank (2) in this position with door window glass closed.
Installation:
Insert rosette (1) with turning lock (2) in opening (3) of door trim
panel.
51 34 191 Replacing left or right fixed door window in rear window frame
Note:
For gluing the door window, glues for cold and hot processing are
permitted.
Remove rubber guide for rear door window glass,
refer to 51 34 211.
Remove window cavity trim from inside of rear door,
refer to 51 22 330.
Remove trim on window frame of rear door (rear),
refer to 51 34 ...
Cold processing:
refer to 51 31 ...
Warm processing:
cartridge oven.
BMW Parts Service).
refer to 51 31 ...
Mask door window and body flange all round with fabric adhesive tape (1)
(e.g. Tesa).
Adhere to cutting depths as specified.

(A) = 24 mm
(B) = 18 mm
(C) = 16 mm
(D) = 20 mm
Carefully cut into corner points.
Fit straight blade with adjustable roller (sourcing reference: BMW Parts
Service) on tool and set dimension (X).
Adjust measurement (X), as specified in previous work step.
Note:
Carefully insert knife blade between body and door window.

Run handle of knife parallel to door window.
Pull door window outwards to remove.
Cut off old glue in body opening to a thickness of approx. 0.5 mm.
To avoid paintwork damage, carefully cut off glue residue with scalpel.
Remove glue tape all round. Clean body aperture with 2-propanol.
Caution!
To provide long-term corrosion protection, always touch up damage
to paintwork (scratches and large areas of damage),
refer to 51 31 ...
Caution!
Treat body around glued area with BMW-approved materials (repair kit,
refer to 51 31 ...
Note:
Only when reusing the door window:
Remove frame (1).
Pull off fabric adhesive tape (2) all round and clean window with 2-
Propanol.
Carefully remove glue residue (3) on door window with a scalpel to a
thickness of approx. 0.5 mm.
Treat door window around glued area (1) with materials approved by
refer to 51 31 ...
Note:
Treat up to max. 2 mm on edge (2) of ceramic surface.
Fit new frame (3).
Cut standard nozzle to size.

(A) 7 mm
(B) 12+1 mm
Note:
Caution!

Cartridge must be perpendicular to door window.
Shape of glue bead:
(A) 7 mm
(B) 12+1 mm
Caution!
Apply glue rapidly and insert door window. Skin forms after 10
minutes.
Carefully fit door window first at bottom with frame in guides (1),
align sides and then install at top and press into position.
Door window is clipped with frame into openings (1) in rear door (2).
Caution!
door window out again for this purpose. Hardened glue can only be
removed by machine.
Assemble car.Note:
Leaks are detected by spraying with water on the sealing lips or by
using an ultrasonic leak tester and can then be sealed with an
appropriate nozzle.
51 34 171 Replacing rear left or right door window

00 9 314
Remove sound insulation on rear door.
Note:
When removing the window lift (51 37 000 or 51 34 020), do not remove
the door window glass.
Only for removal and installation of door window glass:
If necessary, remove trim on window frame of rear door.

A approx. 115 mm
Caution!
If necessary, disconnect battery negative lead.
Slacken screw (1).
Note:
When removing the window lift (51 37 000 or 51 34 020), do not remove
the door window glass (1).
If necessary, push door window glass (1) towards top and secure from
inside with special tool 00 9 314 (adjustment wedges).
Remove door window glass (1) towards top.

Installation:
Each time the door window glass is removed or replaced, the holder (2)
must be replaced.
If necessary, fit new screw (1) and nut (3) on door window glass (4).
Note:
Door window glass does not need to be adjusted.
51 34 211 Replacing rubber guide for rear left or right door window
Remove cover (anti-trapping protection) on inside door window

frame,
refer to 51 34 160.
Remove rubber guide (1).
Installation:
Prior to installation, coat rubber guide (1) with soapy solution
Installation:
Close door window glass (1) a little.
Push rubber guide (2) onto door window glass (1) and into window
guide (3).
51 37 000 Removing and installing complete power window lifter from rear
left and right sides
Release rear door window glass (do not remove),

refer to 51 34 171.
Plug connection (1) must be disconnected from window lifter (2).

Unscrew nuts (3).
Lift out window lifter (1) with stay bolts (2).

Guide window lifter (1) with stay bolts (3) up to point (4) and remove.
Replacement only:
Release screws (1).
Turn flat motor (2)
and detach from window lifter (3).
51 34 191 Replacing left or right fixed door window in rear window frame
Note:
For gluing the door window, glues for cold and hot processing are
permitted.
Remove rubber guide for rear door window glass,
refer to 51 34 211.
Remove window cavity trim from inside of rear door,
refer to 51 22 330.
Remove trim on window frame of rear door (rear),
refer to 51 34 ...
Cold processing:
refer to 51 31 ...
Warm processing:
cartridge oven.
BMW Parts Service).
refer to 51 31 ...
Mask door window and body flange all round with fabric adhesive tape (1)
(e.g. Tesa).
Adhere to cutting depths as specified.

(A) = 24 mm
(B) = 18 mm
(C) = 16 mm
(D) = 20 mm
Carefully cut into corner points.
Fit straight blade with adjustable roller (sourcing reference: BMW Parts
Service) on tool and set dimension (X).
Adjust measurement (X), as specified in previous work step.
Note:
Carefully insert knife blade between body and door window.

Run handle of knife parallel to door window.
Pull door window outwards to remove.
Cut off old glue in body opening to a thickness of approx. 0.5 mm.
To avoid paintwork damage, carefully cut off glue residue with scalpel.
Remove glue tape all round. Clean body aperture with 2-propanol.
Caution!
To provide long-term corrosion protection, always touch up damage
to paintwork (scratches and large areas of damage),
refer to 51 31 ...
Caution!
Treat body around glued area with BMW-approved materials (repair kit,
refer to 51 31 ...
Note:
Only when reusing the door window:
Remove frame (1).
Pull off fabric adhesive tape (2) all round and clean window with 2-
Propanol.
Carefully remove glue residue (3) on door window with a scalpel to a
thickness of approx. 0.5 mm.
Treat door window around glued area (1) with materials approved by
refer to 51 31 ...
Note:
Treat up to max. 2 mm on edge (2) of ceramic surface.
Fit new frame (3).
Cut standard nozzle to size.

(A) 7 mm
(B) 12+1 mm
Note:
Caution!

Cartridge must be perpendicular to door window.
Shape of glue bead:
(A) 7 mm
(B) 12+1 mm
Caution!
Apply glue rapidly and insert door window. Skin forms after 10
minutes.
Carefully fit door window first at bottom with frame in guides (1),
align sides and then install at top and press into position.
Door window is clipped with frame into openings (1) in rear door (2).
Caution!
door window out again for this purpose. Hardened glue can only be
removed by machine.
Assemble car.Note:
Leaks are detected by spraying with water on the sealing lips or by
using an ultrasonic leak tester and can then be sealed with an
appropriate nozzle.
51 31 ... Notes on window bonding
These notes are not applicable for side window bonding (door ”centre”) on E38/L7.
General procedure for disassembly/installation of bonded window glass.
Version with Head‐Up Display (HUD):
Marking for HUD must be present on the windscreen
Adhesive quantities:
Approx. 1 1/4 glue cartridges are required to bond the windscreen on the following vehicles:
7 Series
5 Series from E60
X5
X3
Version with GPS navigation system 1 (up to 09/1997):
After installation of rear window:
Recalibrate magnetic field probe
Refer to functional description in ISID (Integrated Service Information Display)
51 37 000 Removing and installing complete power window lifter from rear
left and right sides
Release rear door window glass (do not remove),

refer to 51 34 171.
Plug connection (1) must be disconnected from window lifter (2).

Unscrew nuts (3).
Lift out window lifter (1) with stay bolts (2).

Guide window lifter (1) with stay bolts (3) up to point (4) and remove.
Replacement only:
Release screws (1).
Turn flat motor (2)
and detach from window lifter (3).
51 41 510 Creating opening for HiFi speaker.

Create opening for HiFi speaker,
refer to 51 42 510.
.
51 48 ... Notes for bonding sound insulation (SI), doors
51 0 300
Attention!
Do not yank at the sound insulation (risk of damage).
General:
Sound insulation is bonded to the inner door panel.
Bonded sound insulation must not be subjected to load (e.g. leak test) before 5 hours have elapsed.
On-the-job safety:
When working with bonding products (adhesive, cleaning agent, etc.):
Ensure the area is well ventilated.
Change work clothing contaminated with adhesive immediately.
Change work clothing contaminated with solvents and swelling agents immediately (keep spare work
clothing on hand).
Take skin protection measures, provide washing facilities including hot water, use silicone-free skin
creams.
Comply with the relevant safety regulations.
Handling adhesive area on inner door panel:
Adhesive Cleaning
a. Cleaning agentR2
a. Butyl bead applied to Under no circumstances: paint thinning
sound insulation with b. Carry out bonding only after an air drying time ≥ 1 min. Air drying time
protective film may be omitted if the entire bonding surface is wiped with a dry cloth
b. Butyl mini-round profile c. After cleaning, the bonding surface may not be touched with hands
∅ 4 mm from the roller or fouled again
c. Butyl round profile ∅ 6 mm
from the roller
Repair in area of sound insulation, door:
Repair
Cut the butyl rope between the sound insulation and the inner door panel with a
sharp knife
After the repair is finished, position a new butyl rope ∅ 4 mm directly on the original
adhesive bead
Heat the butyl bead with a standard hot air blower until the butyl rope strings when
touched slightly. Do not damage the sound insulation in the process
Press on with special tool 51 0 300. Perform this work extremely carefully because
the increased amount of adhesive requires contact pressure of ≥ 20 N/cm2
(compared to firm thumb pressure ~ 30 N/cm2)
Visually check the adhesive bead and its compression (no capillaries or broken
adhesive bead permitted)
in the event of
damaged sound In the cases mentioned, the complete sound insulation must be replaced. After
insulation or removing the sound insulation, removal all butyl remnants from the inner door
leakage panel. Apply 6 mm ∅ butyl rope to new sound insulation
Press on with special tool 51 0 300. Contact pressure ≥ 20 N/cm2 (compare to firm
thumb pressure ~ 30 N/cm2)
The sound insulation must be bonded watertight below the door lock:
Flat bonding surface required all round.
No bonding in the event of moisture (e.g. condensation, etc.).
Bonding area must not show any traces of adhesion-reducing residues (e.g. separating agents, greases,
oils, paraffins, plastisols, cavity wax, polishing dust residues, etc.).
Remove the protective film directly before joining (under no circumstances remove earlier, since the
butyl, because of its stickiness, will very quickly pick up adhesion-reducing dirt contaminants).
The sound insulation must be attached with positional accuracy to the inner door panel because it will no
longer be possible to change the position without damaging the butyl bead.
With repainted areas, the maximum permitted temperature of 90°C may not be exceeded in the area of
the sound insulation. Otherwise, the sound insulation must be removed (and replaced, if necessary).
24 months, see label on packaging.
Disposal of the cleaning cloth:
Cleaning cloths and cleaning agent residues are hazardous waste (see also safety data sheet).
Hazardous waste (see also safety data sheet).
51 41 000 Removing and installing left or right front door trim panel

00 9 317
Warning!
refer to 51 00 ...
Caution!
Do not use any sharp-edged tools to remove the panel - risk of
damage to airbag.
Remove clipped-in trim (decorative strip) from door trim panel at front.
Remove switch for exterior rearview mirror.
Passenger side without removal opening:

Note:
Do not damage lining (2) when removing trim (1).
Using a small screwdriver, carefully lever out trim (1) at points (2).
Passenger side with removal opening (1):Note:

Carefully insert a regular screwdriver approx. 1 mm into removal

opening (1) of trim (3).
Press trim (3) forwards and lift out towards top.
Release screws (1).
Installation:
Screw (1) is longer than the others.
Lever out trims (3), release screws underneath and screws (2).
Installation:
Unclip clips (1) of door trim panel with special tool 00 9 317 (trim panel
wedge).
Carefully unclip door trim panel (1) at top with special tool 00 9 317 (trim
panel wedge).
Feed door trim panel (1) out of unlocking knob (2).
Unhook Bowden cable for release lever:

Tighten release lever (1).
Lever out lock (2).
Remove Bowden cable (3) towards rear/top.
Installation:
Press unlocking lever (1) for installation fully on door trim panel.
Version with additional speaker:
If necessary, disconnect plug connection (1) on additional speaker (2).
Feed out wires (1) from opening (2).

Disconnect plug connections (3) and (4) and remove door trim panel.
Installation:
Clips (1) are longer than the other clips.
Clips (1) are gray,
the other clips are white.
Fit all clips with sealing ring.
If necessary, replace faulty clips.
Caution!
The sound insulation may be damaged at the screw-down points for
the armrest.
If necessary, tape off sound insulation in this area with fabric
adhesive tape.
Installation:
After assembling the door trim panel proceed as follows:
Open door window
Lock with vehicle key
Check whether linkage of safety button can move freely
If necessary, align linkages
51 48 ... Removing and installing/replacing sound insulation in front door,
left or right

00 9 317
Important!
Instructions for sound insulation are an essential part of these
repair instructions and must be followed without fail.
Do not detach sound insulation in jerks (risk of damage).
Ensure watertightness of sound insulation after every repair (water
ingress).

Remove front door trim panel
If necessary, remove airbag module in front door
Using special tool 00 9 317 , lever out sealing bead (1) of sound
insulation (2) completely or if necessary partially.Note:
Work with care in area (A), otherwise sound insulation (2) will tear and
must be replaced (leaks).
Important!
When cutting through sealing bead (1), do not damage sound
insulation (2) and if necessary cable.
With a suitable sharp cutting tool (3) cut through sealing bead (1) of
sound insulation (2) in the area to be detached.
Clean bonding area with adhesive remover (sourcing reference: BMW
Parts Department).
Air drying time: 1 minute
Important!
hands.
Note:
Replacement:
Lay 6 mm dia. butyl rope (sourcing reference: BMW Parts Department) in

specified adhesive area.
Heat butyl rope (hot-air blower) and press down firmly on sound
insulation all round.
Contact pressure with hand roller: approx. 20 N/cm 2
Manual contact pressure: approx. 10 N/cm 2
Note:
Firm thumb pressure has approx. 30 N/cm 2
Note:
Position of butyl rope (1) on inner door panel is identified by centre punch
marks.
Note:
Position of butyl rope (1) on sound insulation (2).
Note:
A marking (2) is provided all round on the sound insulation (1).
Butyl rope (3) rests on or inside the marking (2).
Secure line (1) with 6 mm dia. butyl rope (2) (sourcing reference: BMW
Parts Department).Note:
Lines (3) pass over sound insulation.
51 41 001 Replacing front left or right door trim

refer to 51 41 000.
Unscrew bolts (1).

Remove speaker (2) with insulation (3).
Unlock catches (1) and feed out speaker finisher strip (2) from guides (3).
Version with Hifi system:

If necessary, release union nut (1) and remove speaker (2).

A marking (1) is provided on the new door trim panel (2) for the speaker.
Creating cutout for supplementary speaker:
Replace additional work for door trim panel,
refer to 51 42 510.
51 42 510 Creating opening for HiFi speaker (or window crank)
Note: Door or side trim panel removed.
Note:
The aperture is created with a commercially available hot cutter (1)
with replaceable blades (2).
Warning!
Be careful not to burn yourself when using hot-cutting equipment.
Do not inhale fumes.
When working indoors:
Ensure room is well ventilated.
Remove the fumes generated during cutting with a fume extraction
facility.
Further safety precautions,
refer to operating instructions for hot-cutting equipment.
Position blade (1) of hot cutter inside marking (2), push through and cut
out along marking (2).
Remove remaining area (1) on door trim panel (2) with a scalpel until
flush.
51 42 511 Creating opening for window crank

refer to 51 42 510.
.
51 0 300
Attention!
General:
On-the-job safety:
clothing on hand).
creams.
Adhesive Cleaning
a. Cleaning agentR2
from the roller
Repair
sharp knife
adhesive bead
in the event of
51 42 000 Removing and installing rear left or right door trim panel

00 9 317
Warning!
refer to 51 00 ...
Caution!
Do not use any sharp-edged tools to remove the panel - risk of
damage to airbag.
Remove clipped-in trim (decorative strip) on door trim panel.

Version without power windows:
Remove rear window crank.
Version without power windows and without removal opening:

Note:
Using a small screwdriver, carefully lever out trim (1) at points (2).
Version without power windows and with removal opening (1):Note:

When removing trim (2), do not damage lining (3) with screwdriver.
Carefully insert a regular screwdriver approx. 1 mm into removal

opening (1) of trim (2).
Press trim (2) forwards and lift out towards top.
If necessary, lever out rocker switch (1) at rocker (2),
disconnect plug connection and
remove rocker switch (1).
Release screws (1).

Installation:
Screw (1) is longer than the others.
Lever out trims (3), release screws underneath and screws (2).
Installation:
Unclip clips (1) of door trim panel with special tool 00 9 317 (trim panel
wedge).
Carefully unclip door trim panel (1) at top with special tool 00 9 317 (trim
panel wedge).
Feed door trim panel (1) out of unlocking knob (2).
Unhook Bowden cable for release lever:
- Tighten unlocking lever (1)
- Lift out lock (2)
- Remove Bowden cable (3) towards rear/top.
Installation:
Press unlocking lever (1) for installation fully on door trim panel.

If necessary, feed out lead (1) from door trim panel (2).
Version with additional speaker:
If necessary, disconnect plug connection (3) on additional speaker (4).
Remove door trim panel (2).
Installation:
Clips (1) and (2) are longer than the other clips.
Clips (1) and (2) are gray,
the other clips are white.
Fit all clips with sealing ring.
If necessary, replace faulty clips.
Caution!
The sound insulation may be damaged at the screw-down points for
the armrest.
If necessary, tape off sound insulation in this area with fabric
adhesive tape.
Installation:
After assembling the door trim panel proceed as follows:
Open door window
Lock with vehicle key
Check for ease-of-movement on retaining button linkage
If necessary, align linkages
51 48 ... Removing and installing/replacing sound insulation in rear door, left
or right
Important!
ingress).

Remove rear door trim panel
If necessary, remove airbag module in rear door
Detach clip (2) when completely removing sound insulation (1).
Position of sealing bead (1).Note:

Important!
Parts Department).
Important!
hands.
Note:
Replacement:

Note:
Note
Position of butyl rope (1) on inner door panel.
Note:
marks (2).
Note:
Note:
51 42 001 Replacing left or right rear door trim

refer to 51 42 000.
Version with window crank:

A marking (1) is provided on the new door trim panel for the window
crank.
Make cutout for window crank:
refer to 51 42 510.

If necessary, detach speaker (1) and remove from door trim panel (2).
If necessary, remove speaker cover (1) from door trim panel (2).
Remove loudspeaker.
A marking (1) is provided on the new door trim panel for the speaker.
Make cutout for HiFi speaker:
refer to 51 42 510.
51 43 251 Removing and installing / replacing trim panel for left or right rear
roof pillar (C-pillar)
Lift out side interior light (1) from C-pillar trim and disconnect plug
connection.
Unclip clips (1) and remove trim (2) towards inside/top.
Installation:
If necessary, replace faulty clips (1) and (2).
51 43 201 Removing and installing or replacing trim for front left or right roof
Warning!
Version with head airbag:
refer to 51 00 ...
Caution!
Do not use sharp-edged tools to remove trim (risk of damage to
head airbag).
Remove mucket from front roof pillar (A-pillar finisher).

Remove plate (1).
Release screws (1).

Lift out trim (2) at top (3) and remove towards inside/top.
Installation:
Install screws (1) with washers.
Tightening Torque,
51 43 150 Removing and installing or replacing trim for left or right door
pillar (bottom)

Remove front door sill cover strip
E84 only:
Remove rear door sill cover strip
Snap trim (2) out of clips (1) at bottom.

Feed out trim (2) for door pillar from door sill cover strip (3).
Partially detach edge protection in area of B‐pillar panel.

Carefully feed out bottom trim (1) from top trim (2).
Installation:
If necessary, replace faulty clips (1).
Guides (2) on trim (3) must not be damaged.
51 43 148 Removing and installing or replacing trim on left or right door
pillar (top)

Remove panel for door pillar (bottom)
Release seatbelt screw (1) on front seat and feed out seatbelt strap (2).
Release expansion rivets (1) on panel (2).
Pull off panel (1) towards bottom.

Feed out seatbelt strap (2).
Installation:
Locator (1) and guide (2) on trim (3) must not be damaged.
51 43 070 Removing and installing/replacing side trim panel, footwell, on A-
pillar, left
Remove panel for pedals,

refer to 51 45 185.
Remove front entrance cover strip (inside),
refer to 51 47 000.
Release screw (1) and remove release lever (2).
Remove mucket (1) in area of footwell trim.

Release screw (2).
Push footwell trim (3) a little to rear (guides (3) are unlocked) and detach
footwell trim towards inside.
Installation:
Guides (1) must not be damaged.
Replacement only:
Lift out insert (2) in footwell trim (3).
51 43 075 Removing and installing/replacing side trim panel, footwell, on A-
pillar, right
Remove mucket (2) in area of footwell trim.

Unclip clips (1) towards inside.
Remove side trim panelÂ (2) from entrance strip (3).
Installation:
If necessary, replace faulty clips (1) in side trim panel (2).
51 44 011 Removing and installing / replacing headliner (with slide/tilt
sunroof)
Remove both sun visors and counter supports,

refer to 51 16 080.
Remove all grab handles,
refer to 51 16 480.
Remove both panels for front roof pillar (A-pillar finishers),
refer to 51 43 201.
Remove both panels for top door pillar (B-pillar finishers),
refer to 51 43 148.
Remove both panels for rear roof pillar (C-pillar finishers),
refer to 51 43 251.
Remove interior light and disconnect plug connection.
Remove panel and disconnect plug connection.
Only coupé:
Press on clothes hook (1).
Release screw (2) and remove clothes hook (3) on left/right side.
Solid trim:
Unclip solid trim (1) towards bottom and remove.
Split trim:
Unclip split trim (1) towards bottom and detach towards front.
Solid trim:Installation:
Catches (1) and Velcro-type fasteners (2) on panel (3) must not be
damaged.
Split trim:Installation:
If necessary, replace defective clips (1).
Catches (2) on trim (3) must not be damaged.
Version with interior light package:

If necessary, lever out inside lights on left/right side and disconnect plug
connection.
Release expansion rivet (1) at rear of headliner (2).
Release expansion rivet (1) and screw (2) at front of headliner (3).
Remove mucket (1).Installation:

The joint (2) is located above the driver's side.
Move both front seat backrests as far back as possible.

Press headliner (1) towards rear out of metal lugs (2) and remove
towards rear left door.
Installation:
Slide special tool 51 4 000 via 3rd brake light (1) into locators (2) for
headliner and secure with adhesive tape.
Lettering ”E39” points to roof.
1. Suspend headliner at rear
2. Secure headliner at front with expansion rivet (in left counter
support of sun visor)
3. Screw down grab handles at rear on left/right
4. Screw down grab handles at front on left/right
5. Screw down sun visors and counter supports
6. Screw down headliner at light aperature at front
51 44 001 Removing and installing/replacing headliner (without slide/tilt
sunroof)
Except for the steps relating to the slide/tilt sunroof, the work is
identical to:
Removing and installing/replacing headliner (with slide/tilt sunroof)
51 45 030 Removing and installing instrument panel trim

Remove fixture for steering column switch.
Remove center console.
Remove trim for center console.
Remove all clip-fitted trims (on instrument panel).
Remove carrier in center console.
Remove both panels for front roof pillar.
Remove light switch unit.
Remove complete instrument carrier.
Remove heating controls.
If necessary, remove radio receiver.
Remove airbag module on passenger side.
If necessary, release screw (1).
Remove glovebox light (1) from opening (2).

Disconnect plug connection and remove glovebox lightÂ (1).
Release screws (1).

If necessary, release pin (2).
Remove insert (3) towards bottom.
Feed out wire (1) for glovebox light from guides (2).
Disconnect plug (1) and feed out cable (2) from guides.
Press panel (1) somewhat to rear and remove from guides (2).
Feed out clip (3) on panel (1) to front/right.
Disconnect plug connection (1) and remove panel.Installation:

Retaining pins (2) and clip (3) must not be damaged.
Release screws (1).
Remove defroster nozzle (2) towards rear.
Remove screw or expansion rivet lower section (1).

Instrument panel (2), right.
Slacken nut (1).
Disconnect plug connection (1) for solar sensor.

Unscrew nuts (1).
Move front seats as far back as possible.
Apply handbrake fully.
Pull out instrument panel (2) towards rear and lift out through front right
door.
Installation:
Push guide (1) into locator (2).
Installation:
Screw down shelf (1) and instrument panel trim (2) with screws (3) and
center.
Loosen nut (4).
Center shelf (1) and instrument panel trim (2) and tighten nut (4).
51 45 185 Removing and installing/replacing trim for pedal assembly
Move steering column upwards to max. possible position.
Release screws (1) and expansion rivets (2).

Unlock rotary clip (3) (turn through 90°).
Unlock left/right retaining clips (1) and fold trim (2) down.
Remove and feed out footwell light (1).

Disconnect plug connection (2) from gong.
Release lock (3) and press out plug (4) through opened OBD socket.
Replacement only:
Release locks (5) and remove OBD socket (6).
OBD = on-board diagnosis
Replacement only:
Unlock gong (1) and remove from trim (2).
51 45 031 Replacing instrument panel trim
Remove left fresh air nozzle.

Remove panel for instrument panel.
Unfasten screws (1) and remove bracket (2).

Convertible only:
Stick sketch below to new instrument panel; this is included with the
replacement instrument panel.
Cut out instrument panel at bottom in accordance with sketch.
Detach retainers (1) and remove cover (2) for steering column paneling.
If necessary, release screw (1) and detach air duct (2) on left/right.
Lift fresh air grill (1) above catches (2) and press out.
Remove metal nuts (1) from tunnel (2) of instrument panel.
Passenger side:
Remove retainers (1) and (2).
Remove plastic nuts (3) and metal nuts (4).
Driver's side:
Remove clips (1).
Driver's side:
Remove metal nuts (1) and plastic nuts (2).
Driver's side:
Remove metal nuts (1) and plastic nuts (2).
51 46 005 Removing and installing trim for oddments tray (back shelf with
rear window roller blind and through-loading system)

Removing and installing/replacing trim for oddments tray (back shelf).
51 46 001 Removing and installing trim for oddments tray (back shelf with
rear window roller blind)

51 46 050 Removing and installing/replacing finisher for top of rear apron
Replacing left trunk wheel housing trim ,

refer to 51 47 151.
Release expansion rivets (1) and remove tray (2).
Version with battery in luggage compartment:

Turn rotary clip (1) through 90° and feed shelf (2) out of trunk wheel arch
trim (3).
Version with battery in engine compartment:

Replace right trunk wheel housing trim ,
refer to 51 47 161.
Turn rotary clip (1) through 90° and remove shelf (2).

Lever out caps (2).
Release screws and remove trim (3).
Replacement only:
Lever out trims (1) and caps (2).
51 46 013 Removing and installing/replacing rear window roller blind

51 46 014 Removing and installing/replacing rear window roller blind (with
through-loading system)

51 46 003 Removing and installing/replacing trim for oddments tray (back
shelf with through-loading system)

51 46 000 Removing and installing/replacing trim for rear parcel shelf

Remove rear left/right backrest side section
Remove rear left/right seat belt
Remove rear left/right head restraints
Remove left/right trim panels for roof pillar (C-pillar)
Remove left/right rear speakers
Lever out belt feed trim (1).

Pay attention to catch (2).
Remove belt feed trim (1).
Feed strap (3) out through belt opening.
Disconnect plug connection (3) in speaker opening on right.

Version with roller sun blind:
Unfasten screws (1 and 2).
Coupé from 04/2004 without roller sun blind:
Release screw (1).
Release clip (1) and remove cover (2).

Pull out rear parcel shelf (3) towards front.
Installation:
Make sure guides (1) are correctly seated on rear parcel shelf.
Note:
The operation ”Removing trim for rear parcel shelf” ends here.
Replacement:
Version with roller sun blind:
Remove trim (1).
Press roller sun blind (2) together at (A) in direction of arrow and press
through from (A) to (B).
Remove roller sun blind (2) towards bottom.
Remove trim for head restraints (3).
51 46 004 Replacing trim for oddments tray (back shelf with rear window
roller blind and through-loading system)

51 47 030 Removing and installing / replacing the rear (inside) left or right
rocker panel strip
Remove rear seat,

refer to MG 52.
Note:
For purposes of clarity, shown here without backrest side section.
A Lift out entrance cover strip (1) towards inside from trim (2) of door
pillar.
B Slide entrance cover strip (1) approx. 20 mm forwards out of clips (3)
and remove.
Lever out clips (1) with pliers (head of pliers surface-ground)
Installation:
Guide (1) on bracket (2) must not be damaged.
When installing entrance cover strip, insert guide lug between guide
(1) and door seam (3).
Installation:
If necessary, replace defective clips (1).
Guide lug (2) of entrance cover strip (3) must not be damaged.
51 47 065 Removing and installing/replacing finishing strip at front left or
right entrance
Carefully lever out finishing strip (1)

with special tool 00 9 318 (universal wedge)
from clips (2) towards top.
If necessary, lever clips out of entrance with pliers (head of pliers

surface-ground).
If necessary, replace damaged clips.
Foam tape (1) must be fitted.

Push clips (2) onto finishing strip (3) and align.
51 47 072 Removing and installing/replacing finishing strip on entrance, rear
left or right
Lever out clips (1) towards top with special tool 00 9 318 (universal
wedge).
Carefully remove finishing strip (2) towards rear/top from clipÂ (3).
If necessary, remove clips.

Remove clips from entrance with pliers (head of pliers surface-ground).
Slide on clips (1) and align.

If necessary, replace damaged clips.
51 47 000 Removing and installing/replacing front (inside) left or right
entrance cover strip
Remove entrance cover strip (1) with clips (2) towards top.
If necessary, lever out clips from floor plate.
Installation:
Push clips (1) onto entrance cover strip (2).
If necessary, replace faulty clips (1).
51 47 101 Removing and installing/replacing luggage compartment floor trim
panel
Open trunk lid.
Take out luggage compartment floor trim panel (1).

51 47 161 Removing and installing/replacing right trunk wheel arch trim
Remove socket housing for tail light in side section,

refer to 63 21 055.
Version with through-load system:
Remove rest side section from rear seat backrest,
refer to 52 26 008.

Remove cover for spare wheel/jack.
Pull out emergency release mechanism for tank cap a little.

Unclip cable (1) from clip (2).
Turn rotary clip (1) through 90Â° and remove.

Partially release panel for trunk separating wall.
Partially lever out outer trim (1) and remove trunk wheel arch trim (2).
51 47 151 Removing and installing/replacing trunk wheel housing trim, left
Remove socket housing for tail light in side section,

refer to 63 21 055.
Remove rest side section from rear seat backrest,
refer to 52 26 008.

Remove cover for spare wheel/jack.
Remove warning triangle.

Release expansion rivet (1) and remove fixture (2) for warning triangle.

Release expansion rivet (1).
Partially release panel for trunk separating wall.
Release expansion rivet (1) and remove trunk arch housing trimÂ (2).
51 0 300
Attention!
General:
On-the-job safety:
clothing on hand).
creams.
Adhesive Cleaning
a. Cleaning agentR2
from the roller
Repair
sharp knife
adhesive bead
in the event of
51 48 ... Removing and installing/replacing sound insulation in front door,
left or right

00 9 317
Important!
ingress).

Remove front door trim panel
If necessary, remove airbag module in front door
Using special tool 00 9 317 , lever out sealing bead (1) of sound
insulation (2) completely or if necessary partially.Note:
Important!
Parts Department).
Important!
hands.
Note:
Replacement:

Note:
Note:
marks.
Note:
Note:
Secure line (1) with 6 mm dia. butyl rope (2) (sourcing reference: BMW
Parts Department).Note:
Lines (3) pass over sound insulation.
51 48 ... Removing and installing/replacing sound insulation in rear door, left
or right
Important!
ingress).

Remove rear door trim panel
If necessary, remove airbag module in rear door
Detach clip (2) when completely removing sound insulation (1).
Position of sealing bead (1).Note:

Important!
Parts Department).
Important!
hands.
Note:
Replacement:

Note:
Note
Position of butyl rope (1) on inner door panel.
Note:
marks (2).
Note:
Note:
51 49 000 Removing and installing or replacing trim for trunk lid

Remove retaining strap and tool box (3).
Release expansion rivets (1) and remove trim (2).

51 71 ... Attaching seal on front and rear doors, left or right
If necessary, remove door brake on door pillar,

refer to 51 21 280.
refer to 51 22 280.
Caution!
Even if there is still partial adhesion,
detach seal completely in area A ... B.
Note:
The seal can be detached by continuously overstretching the
rubber at an angle of 15° ... 25° or by using an angled plastic spatula
Front door:
Area A ... B for attaching.
Rear door:
Area A ... B for attaching.
Note:
If replacing complete seal: Procedure same as removing and
installing seal on front door/rear door, left or right,
refer to 51 71 000.
refer to 51 71 200.
Clean adhesive areas on door and seal with adhesive cleaner (sourcing
reference: BMW Parts Service).Note:
Rubber separation serve as marking, do not remove completely.
When coating seal with adhesive cleaner: observe a drying time of
approx. 5 minutes before continuing.
Attach adhesive tape for positioning seal along rubber separations on

door.Note:
Positioning of seal can no longer be determined properly:
If necessary, use positioning aids to install seal (sourcing reference:
BMW Parts Service).
Front door:
In area A ... B, apply a thin and even coat of profile rubber adhesive
(sourcing reference: BMW Service) to adhesive area on front door and
seal.
Width of adhesive area approx. 8 mm
Distance of adhesive area to:
Door seam approx. 1.5 mm
Edge of adhesive tape approx. 1.5 mm
If necessary, edges of positioning aids approx. 1.5 mm
Air drying time approx. 10 ... 15 minutes
Lay seal (1) without stretching as follows and vertically press down hard
to adhesive area:
Next to door seam approx. 1.5 mm
Edge of adhesive tape just covering
If necessary, edges of positioning aids just covering
Caution!
It is not the time spent pressing, but rather the pressure head
(approx. 10 ... 15 N/cm2 ) that is decisive.
Separation of seal after pressing destroys the adhesive layer.
Profile rubber adhesive must be reapplied.
Caution!
Keep adhesive cleaner away from repaired adhesive area of seal.
Note:
Scrape off visible profile rubber adhesive with special tool 00 9 322
(plastic wedge).
If necessary, use adhesive cleaner (sourcing reference: BMW Parts
Service).
Remove adhesive tape (if necessary positioning aids) and assemble

front door.
Rear door:
(sourcing reference: BMW Service) to adhesive area on rear door and
seal.
Edge of adhesive tape approx. 1.5 mm
If necessary, edges of positioning aids approx. 1.5 mm
to adhesive area:
Edge of adhesive tape just covering
Caution!
Caution!
Keep adhesive cleaner away from repaired adhesive area of seal.
Note:
(plastic wedge).
Service).
Remove adhesive tape (if necessary positioning aids) and assemble

rear door.
51 71 447 Removing and installing or replacing panel for cover on left or
right side member
Note: Grommets and clips must be softened in a water bath for

some time prior to installation.
Release expansion rivets (1) at bottom.
Unclip panel (1) from front to rear,

lever out catch (2) and slide panel (1) towards rear out of guide clip (3).
Installation:
If necessary, fit new guide clip (1).
Lever out clips with folding leg and soak in water.

Installation:
Catch (1) and support (2) for guide clip of panel (3) must not be
damaged.
Note:
Take clips (1) out of water shortly before installing panel and clip
onto panel.
Clip clips (1) between markings (2) onto panel.
Installation:
Slide panel at rear onto guide clip,
slide into groove (1)
and clip in rest.
51 13 115 Removing and installing/replacing cowl panel cover
Remove both windshield wiper arms,

refer to 61 61 100.
Remove microfilter for interior ventilation,
refer to 64 31 010.
Unclip cover (1) on cowl panel.
Installation:
If necessary, replace faulty clips (1) in cover (2).
Replacement only:
If necessary, remove seal (1) from cover (2) for cowl panel.
51 71 080 Removing and installing/replacing heater bulkhead

Remove microfilter for passenger compartment ventilation
Unclip retainers (1) and feed cable out of cable duct.
Release screws (1) and remove microfilter housing towards front.
Installation:
Seals on microfilter housing must not be damaged or missing.

Release locks (2) and pull side trim forwards a little.
Remove screws (1) and (2).
Lift out heater bulkhead.
51 71 041 Removing and installing/replacing rear left or right wheel arch
cover
Note: Shown here without rear wheel to illustrate details better.
Release expansion rivet (1), plastic nut (2), and screw (3).
Note:
Version with tire-pressure checking system:
Disconnect plug connection after levering out wheel arch cover (4).
Lever out wheel arch cover (4) and remove.

Installation:
Insert wheel arch cover (4) at top into bumper (5).
Installation:
Guide (1) of wheel arch cover (2) must not be damaged.
Replacement with tire-pressure checking system only:

Release screws (1) and remove receiving antenna (2) from wheel arch
cover (3).
51 71 374 Removing and installing/replacing reinforcement plate on front
axle support

00 9 120
Caution!
Vehicles must not be driven without reinforcement plates.
Driving without the reinforcement plate may damage the front axle.
Screws of reinforcement plate must be tightened to torque and then
tightened down with special tool 00 9 120 (angle-of-rotation
measuring disk).
Note:
Reinforcement plate is fitted in:
Coupés from 11/99
All Convertibles
All E46 models without 4WD from 12/2000
Caution!
From 02/2001, use new 66 mm dia. control arm bearings and a new
reinforcement plate. For these larger control arm bearings, there
must be an impression (1) on the left/right in the reinforcement
plate (2) (risk of damage).
For further information, refer to Replacing control arm bracket.
The difference can only be discerned by the removed reinforcement
plate.
Only cars up to 02/2001 with:
Control arm bearing dia. 66 mm
Old reinforcement plate (2) without impression (1)
Insert a washer* in each case at rear screw-down points between
reinforcement plate and body.
* Sourcing reference: BMW Parts Service
If necessary, remove front underbody protection.
Release screws (1) and (2) and remove reinforcement plate.
Caution!
If necessary, insert washers at screw-down points (1) between
reinforcement plate and body, refer to Fig. R51 2824.
Installation:
Replace screws (1) and (2).
Install all screws
Tighten screws (1) and (2) to torque and then to angle of rotation,
tightening torque, 51 71 3AZ.
51 71 000 Removing and installing/replacing seal on front door, left or right
Remove cover from inside of door window frame,

refer to 51 32 160.
Remove door brake on door pillar,
refer to 51 21 280.
Note:
Positioning of seal must be determined in three areas of front door
with positioning aids to be stuck on.
Positioning aids are supplied with new seals. Individual orders
Clean adhesive areas on paint with adhesive cleaner (sourcing

Positioning aid ”A1” for front left door (positioning aid ”B1” for front right door)
Detach prestamped positioning aid from base.

Positioning aid ”A1” front door, left (door brake).
Positioning aid ”B1” front door, right (door brake).
Align positioning aid with printed help markings (for bores and screw heads) and contact edge (2) on front door and press
down.
Seal of front door must just cover positioning edge (1) when attached.
down.

down.
Note:
In area A ... B, seal on door is stuck on with profile rubber adhesive
(sourcing reference: BMW Service).
Hand seal (1) with open lip facing inwards over door. Pull off positioning
aid protection (liner) from seal in stages.
Caution!
Do not touch adhesive areas.
Stick on seal (1) as follows:

Position white or yellow seal marking on door window frame at top
rear.
Gently press down seal without stretching approx. 1.5 mm next to
door seam and positioning edges up to above-mentioned area A ...
B.
Check positioning of seal, correct if necessary. (Dip max. 3 cm)
Note:
After gentle pressing, the seal can be detached again up to three
times. Do not dirty adhesive area.
Press down seal vertically to adhesive area up to above-mentioned

area A ... B.
Caution!
Detach remaining protective film (liner) from seal.
(sourcing reference: BMW Service) to adhesive area on front door and
seal.
Edges of positioning aids approx. 1.5 mm
to adhesive area:
Caution!
Caution!
Keep adhesive cleaner away from adhesive area of seal.
Note:
(plastic wedge).
Service).
Remove positioning aids and assemble front door.

51 71 200 Removing and installing/replacing seal on rear door, left or right
Remove cover from inside of door window frame,

refer to 51 34 160.
Remove door brake on door pillar,
refer to 51 22 280.
Note:
Positioning of seal must be determined in three areas of rear door
with positioning aids to be stuck on.
Positioning aids are supplied with new seals. Individual orders
Clean adhesive areas on paint with adhesive cleaner (sourcing

Positioning aid ”C1” for rear left door (positioning aid ”D1” for rear right door)

Positioning aid ”C1” rear door, left (door brake).
Positioning aid ”D1” rear door, right (door brake).
Align positioning aid with printed help markings (for bores and screw heads) and contact edge (2) on rear door and press
down.
Seal of rear door should just cover positioning edge (1) when attached.
down.

down.
Note:
In area A ... B, seal on door is stuck on with profile rubber adhesive
(sourcing reference: BMW Service).
Hang seal (1) with open lip facing inwards over door and pull off
positioning aid protection (liner) from seal in stages.
Caution!
Do not touch adhesive areas.
Stick on seal (1) as follows:

Position white or yellow seal marking on door window frame at top
front.
Gently press down seal without stretching approx. 1.5 mm next to
door seam and positioning edges up to above-mentioned area A ...
B.
Check positioning of seal, correct if necessary. (Dip max. 3o cm)
Note:
After gentle pressing, the seal can be detached again up to 3 times.
Do not dirty adhesive area.
Press down seal vertically to adhesive area up to above-mentioned

area A ... B.
Caution!
Detach remaining protective film (liner) from seal.
(sourcing reference: BMW Service) to adhesive area on rear door and
seal.
Edges of positioning aids approx. 1.5 mm
to adhesive area:
Caution!
Caution!
Keep adhesive cleaner away from adhesive area of seal.
Note:
(plastic wedge).
Service).
Remove positioning aids and assemble rear door.

51 72 ... Sealing installation
Note:
The utmost care must be taken when removing all sealings on the
vehicle. Incorrect fitting can lead to wind noise and water ingress among
other things and can affect the ease of closing and opening.
The following instructions only apply to sealing without sealant.

Sealings with sealant must be replaced each time they are
disassembled.
Sealing surfaces must be cleaned.
In general, the following applies:

Sealings on the side frame can be fitted and removed any number
of times.
Sealings must not be damaged or torn.
The clamping surface must be compressed by hand far enough to
ensure that a tight connection on the side flange is still possible.
The sealing shanks may touch each other slightly. A completely
compressed sealing is not permitted.
It is not necessary to use special tools to compress the clamping

surface. This can be done carefully by hand.
The sealings must always be fitted except in the case of blockages.
There is no defined contact pressure.
A new gasket must be fitted if sealings in the tailgate area are
repeatedly fitted and removed (water ingress due to cracked sheet
metal).
Sealings must be checked for correct fit after installation. If
necessary, sealings should be lifted over the adjacent components
using the appropriate tool. Neighbouring components must not be
damaged.
Sealings must be replaced if the metal inlay of the sealing is visible
(corrosion).
Ensure the clamping surface is even all round.

Sealings that are installed with plastic clips fit tightly against the
body. If this is not the case, replace the clips or sealings.
51 72 ... Sealing installation
Note:
The utmost care must be taken when removing all sealings on the
vehicle. Incorrect fitting can lead to wind noise and water ingress among
other things and can affect the ease of closing and opening.
The following instructions only apply to sealing without sealant.

Sealings with sealant must be replaced each time they are
disassembled.
Sealing surfaces must be cleaned.
In general, the following applies:

Sealings on the side frame can be fitted and removed any number
of times.
Sealings must not be damaged or torn.
The clamping surface must be compressed by hand far enough to
ensure that a tight connection on the side flange is still possible.
The sealing shanks may touch each other slightly. A completely
compressed sealing is not permitted.
It is not necessary to use special tools to compress the clamping

surface. This can be done carefully by hand.
The sealings must always be fitted except in the case of blockages.
There is no defined contact pressure.
A new gasket must be fitted if sealings in the tailgate area are
repeatedly fitted and removed (water ingress due to cracked sheet
metal).
Sealings must be checked for correct fit after installation. If
necessary, sealings should be lifted over the adjacent components
using the appropriate tool. Neighbouring components must not be
damaged.
Sealings must be replaced if the metal inlay of the sealing is visible
(corrosion).
Ensure the clamping surface is even all round.

Sealings that are installed with plastic clips fit tightly against the
body. If this is not the case, replace the clips or sealings.
52 13 030 Removing and installing / replacing back-rest frame on left or right
front seat (normal / manual).
Remove backrest frame and backrest cover with support,

refer to 52 13 405.
Model with lumbar supports:
If necessary, remove lumbar cushion on front seat,
refer to 52 13 050.
If necessary, remove valve housing for lumbar support, front,
refer to 52 13 060.
If necessary, remove lumbar support drive mechanism on front seat,
refer to 67 66 010.
If necessary, release screw (1) and remove metal nut (2).
If necessary, remove mat (1) from spring wire (2) of backrest frame (3).
Installation:
If necessary, suspend mat (1) on uppermost spring wire (2) on
backrest frame (3).
52 13 015 Removing and installing / replacing controls on left / right front
seat (normal / manual)
Warning!
The actuating unit for front seats
which was fitted during car production
is different from the spare part.
Actuating unit version (A):

The two adjusting screws (1) and (2) for eccentric disks,
have a commercially available Torx screw head
which is sealed with hot-melt adhesive.
The adjusting screws (1) and (2) must not be adjusted in the
workshop.
The actuating unit may only be removed from
and refitted to the same front seat.
Actuating unit version (B):

The two adjusting screws (1) and (2) for eccentric disks,
are secured with tamper protection in the screw head.
The adjusting screws (1) and (2) must not be adjusted in the
workshop.
The actuating unit may only be removed from
and refitted to the same front seat.
Actuating unit version (C) (spare part):

The two adjusting screws for the eccentric disk have conventional Phillips
heads.
The adjusting screws (1) and (2) can be adjusted in the workshop.
The actuating unit may be fitted to either front seat.
Prior to installation, apply an acid-free grease to thread; the grease
forces the eccentric disk upwards during adjustment
Removing and installing actuating unit:

Remove front seat,
refer to 52 13 000.
Remove outer cover on front seat,
refer to 52 13 040.
Move front seat to basic position:
Caution!
One seat runner is spring-loaded, risk of injury when unlocking.
Operate actuating lever (1) and snap seat runners (2) into position by
sliding.
Operate actuating lever (3) and snap seat cushion (4) into position by
loading.
Operate actuating lever (5) and snap seat backrest (6) into position by
moving.
Lever out rear trim (1), unclip clips (2) and remove trim (1).
Installation:
Catch (1) and clips (2) on trim (3) must not be damaged; replace if
necessary.
Version with seat heater and/or lumbar support:

Slide cable (1) out of fixture (2) of actuating unit (3).
Version with seat heater and/or lumbar support:
Slide cable (1) out of fixture (2) of
actuating unit (3).

If necessary, slide cable (1) out of fixture (2) of
actuating unit (3).
If necessary, disconnect switch (4).
Release expansion rivet (1) and detach rocker (2) (adjustment lever)
from lever (3).Caution!
Do not turn adjustment lever (2) on threaded rod (2).
Lift actuating lever (1) and release screw (2).

Release screws (3) and (4) and detach actuating unit (5).
Installation:
Screw (3) is shorter than the others.
Insert screw (3) for assembly into actuating unit (5).
Tightening torque,
Installation:
Front guide (1) and eccentric disks (2) on actuating unit (3) must not
be damaged.
Replacement of actuating unit version (C) (spare part) only:

Installation:
For adjustment, coat threads (1) with acid-free grease.
The eccentric disks (2) and (4) are carried upwards for adjustment
by the grease.
1. Threads for eccentric disks

2. Eccentric disk for backrest adjustment
3. Actuating lever for backrest adjustment
4. Eccentric disk for seat height adjustment
5. Actuating lever for seat height adjustment
Adjusting actuating unit, actuating unit version (C) (spare part) only:
Adjusting seat height and backrest inclination:
The screw heads of threads (2) must remain clipped in place
Unscrew eccentric disk (1)
Apply acid-free grease to threads (2)
Screw on eccentric disk (1)
Turn eccentric disk (1) to zero position:
straight surface (3) of eccentric disk (1) must be at top.
Note:
The picture does not match the replacement unit, the replacement
unit has Phillips screws.
Install actuating unit.

Press screws (1) and (2) out of hexagon head to seat center and
screw down.
Tightening torque,
Adjust longitudinal seat setting:
Compress unlocking plates (1) and (2) on seat runner on left/right
with gripping pliers (3) (free of play)

Push new coupling link (1) (adjustment lever) onto threaded rod (3)
and secure with expansion rivet (2)

Press actuating lever (1) for longitudinal seat adjustment
downwards and press together locking clip (3) on coupling link (4)
(coupling link (4) is now firmly connected to threaded rod (2))
Install front seat in the car.
If necessary, release expansion rivet (5) and readjust by turning
coupling link (4)
Move front seat to basic position:

Operate actuating lever (1) and snap seat runners (2) into position
by sliding.
Operate actuating lever (3) and snap seat cushion (4)
into position by loading.
Operate actuating lever (5) and snap seat backrest (6)
into position by moving.
Each actuating lever must have clearance until the mechanism is
unlocked
If there is no clearance, the mechanism may be in a semi-unlocked
state (risk of injury in event of an accident)
If there is excessive clearance, the mechanism may not unlock
completely (no adjustment possible)
Carrying out checks of seat height and backrest inclination
adjustment (danger to life of vehicle occupants):
Check backrest inclination:
Front seat must be in basic position
Actuating lever (1) must be in zero position
Pin (2) must rest against pull rod (3)
There must be a clearance (A)
(A) 0 to 0.5 mm
Check seat height:

Front seat must be in basic position
Actuating lever (1) must be in zero position
Metal lever (2) must rest against metal lever (3)
There must be a clearance (A)
(A) 0 to 0.5 mm
52 13 390 Removing and installing / replacing front headrest (normal/
manual)
Move backrest back.

Move headrest (1) as far upwards as possible.
Unlock lock (2) and remove headrest (1).
52 13 041 Removing and installing / replacing inner cover on left or right
front seat backrest (normal/ manual)
Note:
Shown removed for purposes of clarity.
Release screw (1) and remove trim (2).

52 13 040 Removing and installing / replacing outer cover on left or right
front seat back-rest (normal / manual)
Unscrew bolt (1).
Snap out catches (1) at front/rear

and tongue (2) at rear
from cover (3) towards top and
pull outwards a little.
Installation:
Slide tongueÂ (2) into mounts and snap into place.
Lever lugs (1) on cover (3) out of brackets (2).
Lever out cover (1) at rear, detach at front from guide and remove.
If necessary, press down catches (1) on left/right and
remove switch (2) from cover (3).
Installation:
Following parts must not be damaged,
replace cover (4) if necessary:
1. Catches, top
2. Guide, front
3. Lugs, bottom
52 13 198 Removing and installing / replacing rear panel on left or right front
seat backrest (normal/manual)
Remove front seat.
Release clips (1) with side cutting pliers.Note:

Remove clip remainders.
Carefully pull cover (1) with piping (2) out of groove in rear panel (3).
Installation:
The cover piping (1) has a marking (2) which must line up with hole
(3) in rear panel groove (4).
From marking (2), press in piping (1) completely to left and right at
bottom.
Five new repair clips must be fitted after each disassembly.
Release clips (1) (cut through with side cutting pliers).Note:

Remove clip remainders.
Pull rear panel (1) off backrest cover (2).
Installation:
Holes (1) and (2) on rear panel (3) must not be damaged.
Installation:
Slide backrest cover (1) on left/right over clip mount (2).
Installation:
To prevent noise:
Stick felt strip (1) to raised frame area (2).
52 13 060 Removing and installing / replacing valve housing for left or right
lumbar support, front (normal / manual)
Carry out following tasks beforehand:

Remove rear panel on front seat backrest.
Detach backrest cover (1) from backrest frame (2).
Version with lumbar support and backrest width adjustment only:

Detach hoses (1) and (2) at cutting line (heat with hot air blower if
necessary).
1 Hose (blue) upper cushion (lumbar support)
2 Hose (red) lower cushion (lumbar support)
3 Hose (white) right cushion (backrest width adjustment)
4 Hose (white) left cushion (backrest width adjustment)
5 Motor pump unit (drive unit)
Remove drive unit.

Note:
If necessary, gently heat air hose when firmly seated.
Disconnect hoses (3) ... (5) from valve housing (2).

3 Hose (blue) top cushion
4 Hose (red) bottom cushion
5 Hose (transparent), lumbar support pump (on housing black)
Note:
For purposes of clarity, shown here without valve housing.
Installation:
Observe cable guide (1) for backrest heating.
Lay air hoses (2) without kinks through holeÂ (3).
Slacken screw (1) from inside.

Detach valve housing (3) from metal nut (2).
Installation:
Housing parts (1) ... (4) must not be unclipped (leakage).
If housing is unclipped, clip valve housing together.
Check function.
52 13 000 Removing and installing left or right front seat (normal/manual)

Remove head restraint
Adjust front seat as far forward and upward as possible.
Warning!
Read and comply with safety regulations for handling airbag
modules and pyrotechnical belt tensioners.
Improper handling can lead to triggering of the pyrotechnical seat
belt tensioner or side airbag, resulting in injuries.
Saloon only:
Release seatbelt screw (1) and feed out seatbelt strap (2).
All:
Release screws (1) at rear.
Installation:
Replace screws.
Move front seat as far back as possible.
Unclip cover at front.

Release nuts (3) at front.
Installation:
Replace nuts.
Move front seat down and seat runners forward so that they are flush.
Unlock lock (1) and disconnect plug connection (2).
Important!
Cover door sill with protective covers (risk of damage).
Lift out front seat.

Installation:
Carpet must not get between seat rails and floor pan in area of
fastening points (grating noises).

52 15 030 Removing and installing/replacing backrest frame on left or right
front seat (sport/manual)
Remove backrest frame and backrest cover with padding,

refer to 52 13 405.
Replacement only:
refer to 52 13 050.
If necessary, remove valve housing for front lumbar support,
refer to 52 13 060.
If necessary, remove drive unit for lumbar support on front seat,
refer to 67 66 010.
Lift out mount (1) for rear panel

at top and pull off
towards rear/top from backrest frame (2).
Installation:
Catch (1) and guide (2) on mount (3) for rear panel must not be
damaged.
Guide taper (4) must point downwards.

Installation:
backrest frame (3).
52 13 ... Removing and installing/replacing guide for front left or right head
restraint

Remove rear panel on front seat backrest
Guide for head restraint with pushbutton:

Release catches (1) and (2) and slide guide (3) upwards.
Pull guide (1) out of backrest (2).
Installation:
Catches (1) and (2) on guide (3) must not be damaged.
Check that pushbutton (4) works properly.
After installing guide (3), make sure it is properly seated.
Guide for head restraint without pushbutton:
Release catches (1) and slide guide (2) upwards.
Installation:
Catch (1) on guide (2) must not be damaged.
52 13 070 Removing and installing/replacing seat angle adjuster
(normal/manual) on left or right front seat

51 2 100

Remove front seat
Remove actuating unit
Warning!
Torsion bar spring (1) is subject to tension. Risk of injury.
Lever torsion bar spring (1) with special tool 51 2 100 in direction of arrow
from seat angle adjuster.
Feed torsion bar spring (1) out of seat mechanism.
Installation:
Make sure plastic protector is correctly positioned on contact surface
between torsion bar spring and seat mechanism (grating noises).
Release screws (1).

Installation:
Replace Taptite screws (1).
Release screw (2).

Remove seat angle adjuster (3).
Installation:
Slide left and right O-rings onto shaft. Make sure O-rings are correctly
located between seat angle adjuster and seat pan.
52 13 025 Removing and installing/replacing seat mechanism (on front seat
normal/manual), left or right
Remove seat pan and flexmat on front seat,

refer to 52 13 ...
Remove backrest frame on front seat,
refer to 52 13 030.
Remove seatbelt tensioner,
refer to 72 11 030.
Release screw (1) and cable tie (3).

Remove retaining bracket (2) with seat wiring harness from seat
mechanism (4).
52 16 ... Removing and installing/replacing seat pan and flex mat on front left
or right seat (sports/electric)
Remove seat cover with padding,

refer to 52 16 400.
Release left screw (1) and slacken right screw only.

Release left/right screws (3).
Slacken left/right screws (4) only.
Lever out retaining plate (2) on left.
Installation:
Tightening Torque,
Press seat pan (4) upwards, thereby relieving tension on flex mat.
Release screw (1) and remove support (2) from gear (3).
Installation:
Tightening Torque,
Installation:
Using split-pin drift (1), lift support (2) onto guide (3).
Version with seat occupancy detector:

If necessary, unhook control unit (1) and cable (3) from holders (2).
Turn seat pan (1) upwards.
Detach flexmat (2) at rear from mounts (3).
Detach seat pan (1) on left/right backwards/top from mount (2) and
remove.
Detach flexmat (1) from mounts (2) on seat pan (3).
Removing thigh support from seat pan:

Unhook spring (1) from thigh support (2).
Release screws (1) and remove thigh support (2).
If necessary, release screws (1) and remove guide rails (2) from seat
pan (3).
52 13 ... Removing and installing/replacing seat pan and flexmat
(normal/manual), left or right
Remove seat cover with support,

refer to 52 13 400.

Remove left retaining plate (2) downwards.
Installation:
Tightening torque,
Press seat pan (1) upwards, thereby relieving tension on flexmat.
Release screws (1) and remove retaining plates (2).Installation:

Tightening torque,
Unhook cable (1) from holder (2).

remove.

52 13 405 Replacing back-rest cover for left or right front seat (normal /
manual)
Remove rear panel on front seat backrest,

refer to 52 13 198.
Version with seat heating only: expose seat heating cable:

Remove outer cover on front seat:
Manual operation, refer to 52 13 040.
Electrical operation, refer to 52 16 040.
Pull cable (2) out of holder (3).
Model with seat heating only:

Pull out tongue (1).

Lift out Omega clip (1).
Pull out cable (2) from Omega clip (1).
If necessary, disconnect plug connections (3) and (4).
Removal/replacement of backrest frame only:
Detach cover (1) on left/right.
Caution!
Do not under any circumstances turn screw underneath screw (2),
this would destroy the seat frame.
Loosen left/right screw (2).

Detach backrest frame (3) with backrest cover upwards.
Installation:
Replace screws (microencapsulated).
Tightening Torque,
Note:
The operation "Removing complete backrest" ends here.
Removal of backrest cover with padding/replacement of backrest

frame only:
Remove both guides for front head restraint,
refer to 52 13 ...
Version with lumbar support only:

Note:
Valve housing must not be unclipped, leakage.
If the valve housing is unclipped, release screw and clip valve
housing together.
Disconnect hoses (2) and (3) from valve housing (1).

2 Hose (blue), top cushion
3 Hose (red), bottom cushion
Note:
Installation:
Lay air hoses (2) without kinks through hole (3).
Detach backrest cover (1) at sides towards front and remove with
support upwards from backrest frame (2).
Note:
The operation "Removing backrest cover with support" ends here.
Removal of backrest cover from padding, replacing padding:

Release retainers (1) on left/right of backrest cover (2).
Note:
Support (3) is reinforced in this area.
Release all retainers.

Remove backrest cover (1) from padding.
Remove all remnants of retainers from backrest cover (1) and padding.
Installation:
Fold in new clip (2) with special tool 52 0 050.
1. Support
2. Retainer
3. Trim thread in support
4. Trim wire in backrest cover
5. Back-rest cover
Note:
The operation "Replacing support" ends here.
Replacement of backrest cover:

Pull trim threads (1) out of backrest cover.
Cut new backrest cover to size and insert trim threads (1).
2 Seat heater cable
52 13 415 Replacing left or right support for front seat (normal / manual)
This operation is described in section on:

Replacing seat cover on left or right front seat.
52 13 420 Replacing left or right support for front seat back-rest (normal /
manual)

Replacing backrest cover for left or right front seat
52 13 050 Replacing lumbar cushion on front left or right seat
Carry out following tasks beforehand: Removing rear panel

on front seat backrest:
Basic seat
Sports seat
Note:
If necessary, gently heat air hose when firmly seated. Housing
(valve block) must not be unclipped (leaks). If it is unclipped,
release screw and clip housing together.

2 Hose (blue) top cushion
3 Hose (red) bottom cushion
Installation:
Air hoses (2) and (3) must be laid without kinks.
Unhook lumbar cushion (1) from spring wire (2).

Version with seat heating:
Slide cable (3) for backrest heating to one side a little.
Press back support (1) a little.
Turn lumbar cushion (2) and pull out downwards.
Installation:
Check lumbar cushion (1) at top and (2) bottom for damage.
Air hoses (3) must not be kinked.
Installation:
Attach lumbar cushion (1) to third wire (2) above spring (3).
Note:
Installation:
Lay air hoses (2) without kinks through holeÂ (3).
Installation:
Check function.
52 13 410 Replacing seat and backrest covers for front seat (normal/manual),
left or right

Replace seat cover for left or right front seat.
Replace backrest cover for left or right front seat.
52 13 400 Replacing seat cover on left or right front seat (normal/manual)

52 0 050

Remove inner cover
Remove cover (normal/electric) or
outer actuating unit
Release seat occupancy detector:

Release seat occupancy detector
Clear fault memory if necessary
Seat with electric actuating unit only:

Release screws (1).
Pull trim (2) out a little and release screw (3).
Release clip (5) from carrier (4).
Remove trim (2) and carrier (4).
Installation:
Cable holders (1) on carrier (2) must not be damaged.
Pull out tongue (1) on seat cover (2) on left/right.
Detach seat cover (1) from seat frame (2).

If necessary, disconnect plug connection (1) from control unit (2).

If necessary, lever catch (1) towards top and detach cover (2).
Disconnect plug connection (1) from seat heating.
Disconnect plug connection (1) from seat heating.

Expose cable (2).
Release retainers (1) on left/right.

Pull out cover tabs (2) on left/right.
Pull out cover welt (1) completely from seat frame (2).
Installation:
Begin assembly in middle.
Cover piping (1) and seat frame (2) have markings for middle position.
Fold in tongues (1) on seat cover and push through under backrest (2)
towards front.
Model without seat heating and without seat occupancy detector:

Remove seat cover (1) towards front/top.
Version with seat heater and/or with seat occupancy detector:

Pull seat cover (1) forward a little and feed cable (2) out.
Remove seat cover (1) towards front/top.
Installation:
The padding is coated with wax to prevent grinding noises.
Do not remove wax (1) on seat pan (2).
Note:
The operation ”Removing complete seat cushion” ends here.
Replacing support:
Detach retainers (1) at rear left/right from support (2).
Detach all retainers in side area from longitudinal wires (1).

Pull trim wires (1) forward out of seat cover.
Carefully fold back seat cover and release retainers from cross-wires (2).
Remove seat cover from padding.
Important!
Remove all remnants of clips from seat cover and padding.
Installation:
Bend new clips (2) with special tool 52 0 050 .
1. Padding
2. Retainer
3. Trim wire in padding
4. Trim wire in cover
5. Seat cover
Installation:
The padding is coated with wax to prevent grinding noises.
Do not remove wax (1) on padding (2).
Passenger seat only (replacing padding): Installation:

In order to guarantee the function and fastening (adhesive strength) at
the sticking surfaces of sensor mat (1), the foam most not show any
traces of damage!
Replace the foam if it is hardened or damaged particularly in the area of
the sticking surfaces.
Fit new sensor mat (1) for passenger seat occupancy detector.
Align new sensor mat (1) on foam (2).
Feed plug (3) through bore hole (4).
Passenger seat only (replacing sensor mat):

Passenger seat only (replacing padding):
Installation:
Detach liner (1) at individual points and stick sensor mat (2) onto
foam (3).
Note:
The work for ”Replacing support” ends here.
Passenger seat only (replacing sensor mat):

Pull plug (1) out of bore hole (2).
traces of damage at all!
Cut sticking surfaces on sensor mat (3) with cutter knife or razor blade
from foam without damaging the foam.
Carefully remove sensor mat (3) from support (4).
Note:
The operation ”Replacing sensor mat” ends here.
Replacing seat cover:

Remove trim threads (1) from seat cover (2).
Cut new seat cover (2) to size and insert trim threads (1).
Cable (3) for seat heating.
52 14 899 Additional work (normal/ electric) with defective drive for
longitudinal adjustment
Set seat tilt adjustment to max. up setting.
Release screw (1) on actuator drive (2) of longitudinal seat adjustment.
Release screw (1) on servodrive (2) of longitudinal seat adjustment and

remove servodrive (2).
Activate the operating switch for the seat position adjustment:
(A) No function:
- Disconnect plug for longitudinal seat adjustment
- Connect new servodrive and check function
- If servodrive is running, gear is O.K.
- Reassemble front seat
(B) Actuator drive running:
- Transmission for longitudinal seat adjustment defective!
- Continue with
Disassembly of faulty gear for longitudinal seat adjustment
Disassembly of faulty gear (1) for

longitudinal seat adjustment: Note:
For purposes of clarity, the backrest frame and seat cover are
shown removed.
(2) Input shaft

(3) Internal gear
Using a pneumatic saw (1),
cut through drive shaft (2) from rear.
Remove drive shaft (1) from gear (2).
Release screw (1) and remove gear (2).
Over rest of drive shaft (1),

adjust front seat,
release screws on floor panel
and remove front seat.
Note:
If gear (4) is faulty,
detach cover (2),
release screws (3),
and remove gear (4).
Replace seat mechanism on front seat.

52 14 198 Removing and installing / replacing rear panel on left or right front
seat backrest (normal / electric)
Lever out clips (1).Installation:

Replace faulty clips.
Lever out rear panel (1) at bottom towards rear.

Pull rear panel (1) downwards off backrest frame (2).
Installation:
Bores (1) and fastening set (2) on rear panel (3) must not be damaged.
Installation:
Installation:
Mounts (1) on backrest frame (2) must not be damaged.
To install rear panel, first slide into mounts (1) and then slide in at sides at
bottom.
Installation:
Feed rear panel at sides into opening in backrest cover.
Insert rear panel into mounts (1) on left/right of backrest frame (2) and
snap into place.
52 14 000 Removing and installing left or right front seat (normal/electric)

Remove head restraint.
Warning!
Improper handling can lead to activation of the pyrotechnical seat
belt tensioner or side airbag, resulting in injuries.
Adjust front seat as far forward and upward as possible.

Switch off the ignition!
Release seat belt screw (1) and feed out seat belt strap (2).
Adjust front seat maximum distance towards the front and top.
Release screws (1).
Installation note:
Replace microencapsulated screws.

Adjust front seat maximum distance towards rear and bottom.
If necessary, unclip protective caps towards top.

Unscrew nuts (3).
Installation note:
Replace micro-encapsulated nuts.

Adjust seat rails towards the front until they are flush.
Unlock lock (1) and disconnect plug connection (2).
Important!
Cover side sills with protective covers (risk of damage).
Lift out front seat.

Installation note:
Carpet must not get between seat rails and floor panel in area of
attachment points (groaning noise).

52 14 390 Removing and installing or replacing front left or right head
restraints (normal/electric)

Replacing front left or right head restraint (normal/manual).
restraints (standard/electric)

Removing and installing or replacing front left or right head restraints
(standard/manual)
refer to 52 13 390
52 14 030 Removing and installing/replacing backrest frame on front left or
right seat (normal/electric)

Replacing backrest frame on left or right front seat (normal/manual).
52 16 ... Removing and installing/replacing carrier for outer cover on left or
right front seat (sports/electric)
Remove outer front cover.
Release screws, remove lower section.

restraint (normal/electric)

Guide for head restraint with pushbutton:

Release catches (1) and (2) and slide guide (3) upwards.
Installation:
Catches (1) and (2) on guide (3) must not be damaged.
Check that pushbutton (4) works properly.
Guide for head restraint without pushbutton:
Release catches (1) and slide guide (2) upwards.
Installation:
Catch (1) on guide (2) must not be damaged.
52 14 041 Removing and installing/replacing inner cover on front left or right
seat (normal/electric)

Replacing inner cover on left or right front seat (normal/electric).
52 14 040 Removing and installing/replacing outer cover on front left or right
seat (normal/electric)

Remove and install/replace outer cover on front left or right seat
(sports/electric),
refer to 52 16 040.
52 14 070 Removing and installing/replacing seat angle adjuster on left or
right front seat (normal/electric)

Remove front seat
Remove outer cover
Release screws (1).

Release screw (2).
Unclip carrier (3) from seat mechanism at rear.
Unlock plug connection (1) on drive unit (2) and disconnect.
Release screws (1).

Installation:
Release screw (2).

Installation:
52 14 025 Removing and installing/replacing seat mechanism on left or right
front seat (normal/electric)

61 2 071
61 2 074
Carry out following tasks beforehand:

Remove seat pan and flexmat on front seat.
Remove backrest frame on front seat.
Remove seat belt tensioner.
Release screw (1) and cable holder (3).

Remove retaining bracket (2) with seat wiring harness from seat
mechanism (4).
Attach cable 61 2 074 to cable 61 2 071 and connect plug connection (1)
to front seat.
Connect cable 61 2 071 to battery.
Check function.
52 13 ... Removing and installing/replacing seat pan and flexmat
(normal/manual), left or right
Remove seat cover with support,

refer to 52 13 400.

Remove left retaining plate (2) downwards.
Installation:
Tightening torque,
Press seat pan (1) upwards, thereby relieving tension on flexmat.
Release screws (1) and remove retaining plates (2).Installation:

Tightening torque,
Unhook cable (1) from holder (2).

remove.

52 14 060 Removing and installing/replacing valve housing for front left or
right lumbar support (normal/electric)

Replacing valve housing for left or right lumbar support (normal/manual).
52 14 405 Replacing backrest cover for front left or right seat
(normal/electric)

Replacing backrest cover for left or right front seat (normal/manual).
(normal/electric)

Replacing lumbar cushion on left or right front seat (normal/manual).
52 14 420 Replacing padding for left or right front seat backrest
(normal/electric)

52 14 400 Replacing seat cover for left or right front seat (normal/electric)
Operation differs as follows and is described in:

Replacing seat cover without thigh support for left or right front seat.
Replacing seat cover with thigh support for left or right front seat.
52 14 415 Replacing support for left or right front seat (normal/electric)
The operation for removing the padding with/without OC3 mat is

described in:
Replacing seat cover on front seat
52 15 000 Removing and installing front seat (sports/manual), left or right
Operation is identical to: Removing and installing front seat

(normal/manual), left or right.
restraints (sports/manual)

52 15 015 Removing and installing/replacing actuating unit on front left or
right seat (sports/manual)

Remove and install/replace actuating unit on front left or right seat
(normal/manual),
refer to 52 13 015.
Remove backrest frame and backrest cover with padding,

refer to 52 13 405.
Replacement only:
refer to 52 13 050.
If necessary, remove valve housing for front lumbar support,
refer to 52 13 060.
If necessary, remove drive unit for lumbar support on front seat,
refer to 67 66 010.
Lift out mount (1) for rear panel

at top and pull off
towards rear/top from backrest frame (2).
Installation:
Catch (1) and guide (2) on mount (3) for rear panel must not be
damaged.
Guide taper (4) must point downwards.

Installation:
backrest frame (3).
52 15 390 Removing and installing/replacing front left or right head
restraints (sports/manual)

Removing and installing/replacing front left or right head restraints
(normal/manual)
refer to 52 13 390
restraint (sports/normal)

Removing and installing guide for front head restraint
(normal/manual).
52 15 ... Removing and installing/replacing holder for thigh support on front
seat, left or right (sports/manual)

Removing and installing/replacing holder for thigh support on front
seat, left or right (sports/electric).
refer to 52 16 095
seat (sports/manual)

seat (sports/manual)

Remove and install/replace outer cover on front left or right seat
(normal/manual),
refer to 52 13 040.
52 15 198 Removing and installing/replacing rear panel on front left or right
seat backrest (sports/manual)
Lever out clips (1).Installation:

Replace faulty clips.
Lever out rear panel (1) at bottom towards rear.

Pull rear panel (1) downwards off backrest frame (2).
Installation:
Bores (1) and fastening set (2) on rear panel (3) must not be damaged.
Installation:
Installation:
Mounts (1) on backrest frame (2) must not be damaged.
To install rear panel, first slide into mounts (1) and then slide in at sides at
bottom.
Installation:
Feed rear panel at sides into opening in backrest cover.
Insert rear panel into mounts (1) on left/right of backrest frame (2) and
snap into place.
52 15 070 Removing and installing/replacing seat angle adjuster
(sport/manual) on left or right front seat

51 2 100

Remove front seat
Remove actuating unit
Warning!
Torsion bar spring (1) is subject to tension. Risk of injury.
Lever torsion bar spring (1) with special tool 51 2 100 in direction of arrow
from seat angle adjuster.
Feed torsion bar spring (1) out of seat mechanism.
Installation:
Make sure plastic protector is correctly positioned on contact surface
between torsion bar spring and seat mechanism (grating noises).
Release screws (1).

Installation:
Release screw (2).

Installation:
52 15 025 Removing and installing/replacing seat mechanism on left or right

Replacing seat mechanism on left or right front seat (normal/electric).
52 15 405 Replacing backrest cover for left or right front seat (sport/manual)

Replacing backrest cover for left or right front seat (normal/manual).
(sports/manual)

Replace lumbar cushion on front left or right seat (normal/manual),
refer to 52 13 050.
52 15 415 Replacing padding for left or right front seat (sport/manual)

Replacing seat cover on left or right front seat.
(sport/manual)

52 15 400 Replacing seat cover for left or right front seat (sport/manual)

Replacing seat cover for left or right front seat (normal/manual).
52 14 899 Additional work (normal/ electric) with defective drive for
longitudinal adjustment
Set seat tilt adjustment to max. up setting.
Release screw (1) on actuator drive (2) of longitudinal seat adjustment.
Release screw (1) on servodrive (2) of longitudinal seat adjustment and

remove servodrive (2).
Activate the operating switch for the seat position adjustment:
(A) No function:
- Disconnect plug for longitudinal seat adjustment
- Connect new servodrive and check function
- If servodrive is running, gear is O.K.
- Reassemble front seat
(B) Actuator drive running:
- Transmission for longitudinal seat adjustment defective!
- Continue with
Disassembly of faulty gear for longitudinal seat adjustment
Disassembly of faulty gear (1) for

longitudinal seat adjustment: Note:
For purposes of clarity, the backrest frame and seat cover are
shown removed.
(2) Input shaft

(3) Internal gear
Using a pneumatic saw (1),
cut through drive shaft (2) from rear.
Remove drive shaft (1) from gear (2).
Release screw (1) and remove gear (2).
Over rest of drive shaft (1),

adjust front seat,
release screws on floor panel
and remove front seat.
Note:
If gear (4) is faulty,
detach cover (2),
release screws (3),
and remove gear (4).
Replace seat mechanism on front seat.

52 16 000 Removing and installing front seat (sports/electric), left or right

Removing and installing front seat (normal/manual), left or right.
restraints (sport/electric)

Removing and installing or replacing front left or right head restraints
(standard/manual)
refer to 52 13 390
front seat (sport/electric)

Replacing backrest frame on left or right front seat (sport/manual).
52 16 ... Removing and installing/replacing carrier for outer cover on left or
right front seat (sports/electric)
Remove outer front cover.
Release screws, remove lower section.

52 16 390 Removing and installing/replacing front head restraint
(sports/electric) on left or right

restraint (sports/electric)

Removing and installing guide for front head restraint
(normal/manual).
seat (sports/electric)

52 16 025 Removing and installing/replacing left or right seat mechanism (on
sport/electric front seat)
Remove seat pan and flexmat on front seat,

refer to 52 16 ...
Remove backrest frame on front seat,
refer to 52 13 030.
Remove seatbelt tensioner,
refer to 72 11 030.
Disconnect all plug connections (1) from actuator drives.

Remove seat wiring harness from seat mechanism (2).
Installation:
Connect cable 61 2 071 to battery,
connect cable 61 2 074 to cable 61 2 071 and plug connectionÂ (1)
to front seat.
52 16 050 Removing and installing/replacing lumbar cushion on front left or
right seat (sports/electric)

Replace lumbar cushion on front left or right seat (normal/manual),
refer to 52 13 050.
seat (sports/electric)
Unscrew bolt (1).
Removing top cover:
A Snap out catch (1) on front cover (2) towards bottom and
pull cover (2) outwards a little.
B Snap out catch (3) on rear cover (2) towards front/bottom and
pull cover (2) outwards a little.
Lever lugs (1) on cover (3) out of brackets (2).

Lever out cover (1) at rear, detach at front from guide and remove.
Installation:
Do not crush cables (1) during installation.
Insert lugs (2) into mounts (3) and snap into place.

Lever out lugs (2) and detach switch combination (3).
Installation:
Guides (1) and catches (2) on switch combination (3) must not be
damaged.
If necessary, expose cable (1) and disconnect plug connection (2).
Replacement only:
If necessary, press down catches (3) on left/right and
remove switch (4) from cover.
Installation:
Following parts must not be damaged,
replace cover (4) if necessary:
1. Mounts for switch combination
2. Guide, front
3. Tabs
Replacement of switch combination only or in event of further work on

front seat:
Disconnect plug connection (1) and remove switch combination (2).
52 16 198 Removing and installing/replacing rear panel on front left or right
seat backrest (sports/electric)

Removing and installing/replacing rear panel on left or right front seat
backrest (normal/electric)
52 16 070 Removing and installing/replacing seat angle adjuster on left or
right front seat (sport/electric)

Remove front seat
Remove outer cover
Release screws (1).

Release screw (2).
Unclip carrier (3) from seat mechanism at rear.
Unlock plug connection (1) on drive unit (2) and disconnect.
Release screws (1).

Installation:
Release screw (2).

Installation:
52 16 ... Removing and installing/replacing seat pan and flex mat on front left
or right seat (sports/electric)
Remove seat cover with padding,

refer to 52 16 400.

Lever out retaining plate (2) on left.
Installation:
Tightening Torque,
Press seat pan (4) upwards, thereby relieving tension on flex mat.
Release screw (1) and remove support (2) from gear (3).
Installation:
Tightening Torque,
Installation:
Using split-pin drift (1), lift support (2) onto guide (3).

If necessary, unhook control unit (1) and cable (3) from holders (2).
remove.
Removing thigh support from seat pan:

Unhook spring (1) from thigh support (2).
Release screws (1) and remove thigh support (2).
If necessary, release screws (1) and remove guide rails (2) from seat
pan (3).
52 16 ... Removing and installing/replacing thigh support holder on front
seat, left or right (sports/electric)
Note:
Unlatch the thigh support and pull forward completely.
Loosen the cushion for the thigh support:

Bend the retaining plates (1) up and lift the upholstery bead (2) out.
Note:
The cushion (1) is bonded to the support (2) with double-sided
adhesive tape (3).
Pull the cushion (1) off the support (2) upward.
Lift the trim wire (1) out of the fixtures (2).Installation note:
Apply new double-sided adhesive tape (4) to the support (3) or
bond the facing with spray adhesive.
Note:
The work scope "Remove cushion for thigh support" ends here.
Removal of "Support for thigh support" only:
Detach the spring (1) from the bottom of the support (2) and detach the
seat frame (3).
Release screws (1).

Completely press the operating lever (2) and pull the support (3) for the
thigh support forward and off the seat frame (4).
Installation note:
The following parts on the support (5) may not be damaged:
1 Fixtures for trim wire
2 Hold-down device for trim wire
3 Guide bushes
4 double-sided adhesive tape (replace or mist with spray
adhesive for installation)
Installation note:
If necessary, release screws (1) and remove guide rails (2) from
seat frame (3).
52 16 405 Replacing backrest cover on front left or right seat (sports/electric)
Remove rear panel from front seat backrest,

refer to 52 15 198.
Unhook ends of tensioning cord (1) from backrest frame (2).
Installation:
Pass tensioning cord (1) with backrest cover (3) on left/right round
clip mount (2).
Hook ends of tensioning cord to backrest frame,
refer to previous work step.
Installation instruction for backrest width adjustment:

Lay tension cables (1...2) underneath hoses (3) and cables (4).
Exposing cable for seat heating on version with seat heating only:
Removing outer cover on front seat:
Manual controls, refer to 52 13 040.
Electrical controls, refer to 52 16 040.

Pull out tongue (1).

Pull out cable (2) from Omega clip (1).
If necessary, disconnect plug connections (3) and (4).
Removal or replacement of backrest frame only:

Caution!
Do not under any circumstances turn screw underneath screw (2),
this would destroy the seat frame.
Press backrest cover (1) to one side and release screw (2) on left/right.
Detach backrest frame (3) with backrest cover upwards.
Installation:
Replace screws (2) (microencapsulation).
Tightening torque,
Note:
The work for ”Removing complete backrest” ends here.
Removal of backrest cover with padding or replacement of backrest
frame only:
Remove both guides for head restraint at front,
refer to 52 13 ...
Version with lumbar support only:

Note:
Valve housing must not be unclipped: leakage. If the valve housing
is unclipped, release screw and clip valve housing together.
2 Hose (blue), top cushion

3 Hose (red), bottom cushion
Note:
Installation:
Lay air hoses (2) without kinks through hole (3).
Version with lumbar support and backrest width adjustment only:

Detach hoses (1) and (2) at cutting line (heat with hot air blower if
necessary).
1 Hose (blue) upper cushion (lumbar support)
2 Hose (red) lower cushion (lumbar support)
3 Hose (white) right cushion (backrest width adjustment)
4 Hose (white) left cushion (backrest width adjustment)
5 Motor pump unit
Detach backrest cover (1) at sides towards front and remove with
support upwards from backrest frame (2).
Note:
The work for ”Removing backrest cover with padding” ends here.
Removal of backrest cover from padding, replacing padding:

Release retainers (1) on left/right of backrest cover (2).
Note:
Support (3) is reinforced in this area.
Note routing of tensioning strap (4).
First detach clips (1).

Fold back piping (2) with backrest cover (3).
Detach all remaining clips.

Remove backrest cover (1) from padding.
Remove all remnants of retainers from backrest cover (1) and padding.
Installation:
Fold in new clip (2) with special tool 52 0 050.
1. Support
2. Retainer
3. Trim thread in support
4. Trim wire in backrest cover
5. Backrest cover
Note:
The work for ”Replacing padding” ends here.
Replacement of backrest cover:

Pull trim threads (1) out of backrest cover.
Cut new backrest cover to size and insert trim threads (1).
2 Seat heater cable
(sport/electric)

52 16 400 Replacing seat cover for left or right front seat (sports/electric)

52 0 050

Remove front seat
Remove outer cover with actuating unit
Remove inner cover
Release seat occupancy detector:

Release seat occupancy detector
Clear fault memory if necessary

If necessary, disconnect plug connection (1).
Release cable strap (2).
Detach cable (3) from holder (4).
Detach cable (1) from holder (2).

Release screw (1) on inside/outside.
Unclip clips (3) towards bottom and pull trim (2) out a little.
Release screws (1).

Pull trim (2) out a little and release screw (3).
Release clip (5) from carrier (4).
Remove trim (2) and carrier (4).
Installation:
Cable holders (1) on carrier (2) must not be damaged.
Installation:
Clips (1) on sports seat trim (2) must not be damaged.
Note:
The operation ”Removing holder for actuation” ends here.
If necessary, disconnect plug connection (1) from control unit (2).

If necessary, release locks (1) and detach plug housing (2).
If necessary, press lock (1) downwards and detach cover (2).
Disconnect plug connection (1) for seat heating from plug housing (2).
Pull cable (1) out of holders (2).
E46 only:
Pull out tongue (1) on seat cover (2) on left/right.
Detach seat cover (1) from seat frame (2).
Pull out cover welt (1) completely from seat frame (2).
Fold in ends (1) on seat cover and push through under backrest (2)
towards front.
Unfasten thigh support and pull completely towards front.

Bend open retaining plates (1) and remove cover piping (2).
Note:
Cushion (1) is secured at front with double-sided adhesive tape (3) to
carrier (2).
Pull cushion (1) towards top off carrier (2).
Lever trim wire (1) out of mounts (2).Installation:

Stick new double-sided adhesive tape (4) to carrier (3) or attach mount
with spray adhesive.
Model without seat heating and without seat occupancy detector:
Remove seat cover (1) with thigh support (2) towards front/top.
Model with seat heating and/or with seat occupancy detector:

Pull seat cover (1) forward a little and feed cable (2) out.
Remove seat cover (1) with thigh support towards front/top.
Note:
The operation ”Removing complete seat cushion” ends here.
Replacing padding or sensor mat:

Release clips (1) and (2) at rear left/right from support (3).
Release all clips (1) on left/right and centre (2) from support (3).
Version with seat heating: Installation:
Note routing of seat heater cable (1).
Do not damage with clips.
Detach all retainers in side area from longitudinal wires (1).

Pull trim wires (1) forward out of seat cover.
Carefully fold back seat cover and release retainers from cross-wires (2).
Remove seat cover from padding.
Important!
Remove all remnants of clips from seat cover and padding.
Remove padding (1) from seat cover (2).
Version with seat heating: Installation:

If necessary, detach heating mat (1) from adhesive tape (2) of thigh
support.
3 Seat heater cable
Stick double-sided adhesive tape (2) to support (1) or coat with spray
adhesive.
Version with seat heater and/or with seat occupancy detector:

Installation:
Feed seat heater cable (1) through bore hole (3).
Feed seat heater cable (2) through bore hole (4).
Installation:
Bend new clips (2) with special tool 52 0 050 .
1. Padding
2. Retainer
3. Trim wire in padding
4. Trim wire in cover
5. Seat cover
Installation:
Support (2) must be coated with wax (1) to prevent grinding noises.
Do not remove wax (1) on padding (2).
Passenger seat only (replacing sensor mat): Installation:
traces of damage at all!
Lay sensor mat connection without creasing into groove on support.
Fit new sensor mat (1) for passenger seat occupancy detector.
Align new sensor mat (1) on foam (2).
Feed plug (3) through bore hole (4).
Installation:
Detach liner (1) at individual points and stick sensor mat (2) onto
foam (3).
Note:
The operation ”Replacing support or sensor mat” ends here.
Replacing seat cover:

Remove trim threads (1) from seat cover (2).
Cut new seat cover (2) to size and insert trim threads (1).
3 Seat heater cable
52 16 415 Replacing support for left or right front seat (sport/electric)
The operation for removing the padding with/without OC3 mat is

described in:
Replacing seat cover on front seat
52 24 005 Removing and installing / replacing rear seat (normal)
Operation is identical to: Removing and installing/replacing left

or right rear seat (through-loading system).
52 24 390 Removing and installing/replacing rear head restraints (normal)
Operation is identical to: Remove rear head restraints (through-

loading system).
52 24 400 Replacing seat cover for rear seat (normal)

Replace seat cover,
refer to 52 26 400.
52 26 301 Removing and installing / replacing actuating mechanism for left
rear seat backrest (through-loading system)
Remove and install lock for rear seat backrest (through-loading

system),
refer to 52 26 309.
For saloon/sedan only:

Loosen screws (1).
Unlock catch (2) and at same time unclip mechanism (3) towards bottom.
Unclip Bowden cable from mounting (4).
Installation:
Catches (1) of mechanism (3) must not be damaged.
Bowden cable (2) must be engaged correctly in mechanism (3).
For Coupé only:

Loosen screws (1).
Unlock catch (2) to middle of car and at same time unclip mechanism (3)
towards bottom.
Unclip Bowden cable from mounting (4).
Installation:
Catches (1) and (2) of mechanism (3) must not be damaged.
Bowden cable (4) must be engaged correctly in mechanism (3).

52 26 008 Removing and installing/replacing left/right sides of backrest on
rear seat backrest (through-loading)
Release rear-seat backrest and fold forward.

Unclip top section of backrest (1) and pull upwards (2) to remove.
Important!
For installation, clip (1) must be in rest side section, otherwise the
rest side section will be damaged.
Installation:
Unscrew clip (1) towards top out of plate.
Installation:
Slide clip (1) into mounting (2) of rest side section.
Installation:
Push guide (1) into mounting (2) and guide (3) into mounting (4).
52 26 309 Removing and installing/replacing lock for rear seat backrest
(through-loading system), left
Unlock rear seat backrest and fold down.

Unclip Bowden cable from mountingÂ (1).
Note:
If rear seat backrest cannot be unlocked, release screws (2) and
feed lock out of installation opening with backrest.
Pull lock (1) out of installation opening a little and unclip Bowden cable
(2).
Remove lock completely from installation opening.
Installation:
Catches (2) on lock must not be damaged.
Bowden cable must be anchored correctly in catches (2).
Installation:
Slide guide lug (1) of lock into opening (2).
Note:
Adjustment of lock:
- Slacken screws
- Firmly push engaged backrest back
- Tighten down screws
52 26 390 Removing and installing/replacing rear head restraints (through-
loading system)
Move head restraint up as far as possible.

Forcefully pull out head restraint or detach by hitting firmly on one side
from below.
Pull out guide rods by twisting them back and forth.Caution!

Do not damage rear window.
Installation:
Notches (1) on guide rods must point in direction of catch spring (2).
52 26 005 Removing and installing/replacing rear seat (through-loading
system)
4-door models only:

Unclip rear seat on left/right towards top.
For op. ext. seat heating only:
Disconnect cable.
Lift out seat.

Installation:
Feed belt buckles and lap beltÂ (1) through intended openings into
correct position.
2-door models only:

Unclip rear seat on left/right towards top.
For op. ext. seat heating only:
Disconnect cable.
Pull out seat (if necessary under armrests) towards front.

Installation:
Feed belt buckles and lap belt through intended openings into
correct position.
If necessary, make sure ISOFIX covers are correctly engaged.
Warning!
before removing.
Important!
3. Slide clamp back
Installation note:
52 26 400 Replacing seat cover for rear seat (through-loading system)
Remove rear seat,

refer to 52 26 005.
Feed tightening strap (1) out of wire (2).
Note position of clips.

Cut through or bend open all clips.
If possible, feed cover out of wire loop.
Carefully pull off cover and in so doing cut through or bend open clips of
trim wires.
Remove all remnants of clips from cover and support.
Installation:
Lock new clips by bending with special tool 52 0 050. If necessary,
surround existing wire in foam seat with clips.
If possible, feed trim wires into new cover.

temperature.
Installation note:
curing)
accident).

All MINI
All other BMWs Yes
All MINI Yes
54 10 ... Repair instructions for bonded seals
1 General remarks on handling rubber seal profiles:
If seals reveal partly detached protective film on delivery, they must not be bonded.
Store seals at 5 °C to 40 °C.
If, during the handling, the protective film has come off before bonding, it can still be bonded.
Bonding at room and object temperature 25° ±5° C. Temperatures between 40 and 50 °C significantly
increase initial adhesion.
Seals, which are subjected to temperatures above 80 °C after bonding, will be very difficult to remove.
Maximum storage time for replacement: see identification of the expiry date on packaging
2 Damage pattern, repair and replacement
A partially released bonding (rubber part adhesive tape or adhesive tape paint) up to 120 mm may be finished.
Continue with Point 2.1.
A partially released bonding (rubber part adhesive tape or adhesive tape paint) above 120 mm may not be
finished. Gasket must be replaced. Continue with Point 2.2.
2.1 Repair of partially released bonding (adhesive tape rubber part or adhesive tape paint
2.1.1 Clean faulty areas
Release adhesive area of paint side from recesses and degrease with cleaning agent R2. Stick to air
drying time > of 1 minute. Never use paint thinner!
This will usually partially destroy intact edge adhesive areas.
When removing, it is important to wipe off the adhesive area of the adhesive tape with a lint-free
disposable cloth. (e.g. Kimtex blue, see BMW Parts Department)
Carefully wipe off the adhesive areas.
Note:
Use necessary cotton- or fluff-free paper towel once only.
Do not touch the adhesive area after cleaning.
2.1.2 Apply adhesive

Apply profile rubber adhesive evenly as a thin layer first on the gasket and then on the painted surface.
Stick to air drying time of 2 to 3 minutes.
Important:
Avoid contact with skin!
Do not apply adhesive to visible painted surfaces.
2.1.3 Press in rubber seal

Press down gasket using contact pressure (forced pressure not necessary) for > 1 minute.
Important:
Load can be applied to the bonding only after a period of 2 minutes. This waiting time is absolutely
essential.
2.2 Replacement
2.2.1 Peeling off the faulty rubber seal
Beginning at the stop, the gasket with the adhesive tape is slowly separated from the paint.
The gasket is slowly pulled off from an angle of approx. 20° while applying even tensile stress.
If the gasket is pulled off too quickly, the adhesive tape can tear off and remain on the painted surface.
The adhesive tape remaining on the painted surface must be removed with high cleaning costs.
Note:
When the adhesive tape separates from the gasket, the adhesive tape remaining on the paint must
be fully separated at one location by approx. 10 mm until it is easy to grip.
Pull off the adhesive tape by pulling strongly at an angle of approx. 20°.
When existing gaskets are being peeled off with a hot air blower: Do not damage paintwork.
2.2.2 Clean bonding surface

if required, remove adhesive remains with eraser disk, do not damage paint.
Before a new bond, degrease the entire adhesive area with cleaning agent R2. Stick to air drying time > of
1 minute.
Note:
Use necessary cotton- or fluff-free paper towel once only.
Do not touch the adhesive area after cleaning.
2.2.3 Pull off protective film of the bonding surface

Pull off the protective film off of the new gasket by approx. 15 cm using the tab.
Important:
Once the protective film has been removed, do not under any circumstances touch the exposed
bonding surface.
2.2.4 Apply rubber seal

Press on the gasket by hand continuously while pulling off the liner slightly at the same time.
Note:
If positioned incorrectly, the gasket can still be pulled off, repositioned and pressed on again.
Always ensure that you do not touch the bonding surface with your fingers or contaminate it in any
way.
Compress the gasket the corners; never stretch it. (critical area)
2.2.5 Establish sealing joint
Where the beginning and end meet, a mark is created from pressing the loose end onto the beginning of
the gasket.
Cut off the gasket vertically along the marked line (use sharp knife or special scissors) and press in place.
Visually check the pre-bonded gasket.
Note:
Small areas of gasket can remain stuck to adhesive tape of loose end.
2.2.6 Press gasket

Press gasket by hand or hand roller
Adhesive tape width up to 5 mm, contact pressure > 5 N/cm2
Adhesive tape width up to 10 mm, contact pressure > 10 N/cm2
Note:
Firm thumb pressure has approx. 35 N/cm2
3 Checking the rubber seal

Check the bonded gaskets for correct positioning and perfect adhesion. The bonding can be checked by
pressing back the sealing lip.
The peel strength of the gasket must be greater than 10 N/cm2 for about 15 min after bonding.
54 12 003 Adjusting glass slide/tilt sunroof lid

00 9 315
Close glass sunroof lid (zero position).
Ideal adjustment:
Distance:
Distance (A) between lid and front and rear of roof must be the
same.
Slide a credit card or identity card in between seal and lid. The
card must show the same resistance.
Height:
Front - flush to 1 mm deeper
Rear - flush to 1 mm higher
Adjustment/removal of glass slide/tilt sunroof lid:

Slowly slide headliner (floating) towards rear up to distance (A).
Slacken screws (1) on left/right.Note:

For adjustment, only slacken screws (1) to such an extent that glass
sunroof lid (2) is still just adjustable.
To remove glass sunroof lid (2), release screws (1) completely.
Height adjustment:
Adjust height of lid (1) to roof (2) with special tool 00 9 315 (gap wedge).
Press glass sunroof lid at front and rear upwards/downwards until ideal
position is obtained.
Distance adjustment:
Slide glass sunroof lid forwards/back until ideal position is obtained.
Check function and adjustment.
Replace screws (1) when removing and installing glass sunroof

lid (2).Installation:
Installation:
Initialize sunroof.
Slowly pull headliner (floating) fully towards front.

54 0 ... Notes on steel and glass slide/tilt sunroofs
(initialization/normalization/learning of characteristic curve)
Note:
Initialization comprises:
Normalization
Learning characteristic curve
The mechanical end positions are recorded and stored during
normalization.
The characteristic curve is learnt immediately after normalization.
When the characteristic curve is learnt, the mechanical closing forces of
the slide/tilt sunroof are recorded and stored for correct operation of the
anti-trapping mechanism.
Note:
An initialization must be performed:
In the event of malfunctions, e.g. no one-touch function, no opening
or no comfort function possible.
After disengagement of the drive unit.
If necessary, after an interruption of the power supply.
After work is carried out on the mechanism of the slide/tilt sunroof.
Note:
The initialization sequence is dependent on the software version of the
slide/tilt sunroof module (in the sunroof drive unit).
If necessary, code slide/tilt sunroof drive unit.
Warning!
There is no anti-trapping protection during initialization.
Normalization:
Press and hold the switch in the ”Lift” direction.

In the event of delayed starting or sudden stopping of the slide/tilt
sunroof, continue pressing the switch in the ”Lift” direction.
After reaching lift end position (A), keep switch pressed for approx.
20 seconds further.
Normalization is completed when the slide/tilt sunroof in lift end
position (A) presses again briefly in the direction of position (B).
Release switch.
Learning characteristic curve:
E38 from 9/98; replacement of drive unit

E39 from 3/98
E46 Compact
E46 Saloon, Touring, Coupé from 09/2001; initial equipment of drive
unit
E46 Saloon, Touring, Coupé; replacement of drive unit
E53 slide/tilt sunroof (not: panoramic glass sunroof):
The curve is learnt manually in the following steps:
Release switch after normalization for max. 5 seconds.
Then hold down the switch in the raising position direction until such
time that the slide/tilt sunroof has returned to the closed position
after a complete opening movement.
This concludes learning of the curve. The switch can now be
released.
Note:
Carry out function check (one-touch function, anti-trapping protection
and, if necessary, comfort function).
E38 up to 9/98; initial equipment and replacement of drive unit

E39 up to 3/98:
In these cars, the curve is learnt automatically during operation by way of
the module.
After normalization, open and close slide/tilt sunroof fully once by
pressing switch.
In the event of faulty triggering of the anti-trap protection facility in specific
positions, the fault can be rectified by moving over the relevant position
numerous times.
E38 from 9/98; initial equipment of drive unit

E46 Saloon, Touring, Coupé up to 09/2001; initial equipment of drive
unit:
The curve is determined by means of coding.
54 12 497 Removing and installing / replacing wind deflector for glass
sliding/tilting sunroof
Open glass sunroof lid.

Press down wind deflector (1).
Release screws (2).
Remove spring (3) on left/right and wind deflector (1).
Installation:
Installation:
If necessary, replace faulty spring (1) and screw (2).
54 12 211 Removing and installing complete glass slide/tilt sunroof (frame)
Remove headliner.
Note:
Close glass slide/tilt sunroof lid.
Move front seats backwards/downwards as far as possible.
Remove glass slide/tilt sunroof with a second person helping.
Detach all water drain hoses (1).
Disconnect plug connection from glass sunroof drive.

Release screws (1) and remove glass sunroof frame (2).
Installation:
Note:
In production, the screws (1) are secured with the washers (2) by
robots.
In hand assembly, the washers (2) are not fitted.
54 12 115 Removing and installing glass sliding/tilting sunroof lid

Adjust glass slide/tilt sunroof cover,
refer to 54 12 003.
.
54 12 136 Removing and installing/replacing headliner for glass slide/tilt
sunroof lid
Installation: If headliner is difficult to move, apply a light coat of

Renax GL1 (manufactured by Fuchs) to guide duct.
Remove glass sunroof lid.
Slowly pull headliner (floating) fully towards front.
Release screws (1) from sliding member (2).Installation:

Press headliner (1) to right against springs and at same time detach
sliding member (2) from guide duct (3) and headliner (1).
Installation:
Rear sliding member (1) must be fitted behind driver (2).
Pull headliner (1) to left/upwards with sliding members (2) out of rail (3).
Pull sliding member (1) at front/rear off springs (2) of headliner (3).
Installation:
Nubs (2) of spring (1) must snap into place in guides (4) of sliding
member (3).
54 12 138 Removing and installing/replacing water gutter for glass slide/tilt
sunroof (from 09/2001)

Remove glass sunroof lid.
Unhook lever (2) of water gutter on left/right from rail (1).Installation:

Make sure lever (1) is correctly locked.
Pull water gutter forwards until roller (2) can be seen through opening in
guide channel (3).
Lever (1):
on right side to be pulled upwards
on left side to be unhooked from guide channel
Installation:
Following parts of water gutter must not be missing or damaged:
1 Roller
2 Lock
3 Rubber seal
Check function.
54 12 646 Replacing glass slide/tilt sunroof frame
Note: Glass slide/tilt sunroof (frame) completely removed
If necessary, remove complete glass slide/tilt sunroof (frame).

Remove headliner for glass slide/tilt sunroof lid.
54 12 116 Replacing glass sliding/tilting sunroof lid

Replace seal for glass slide/tilt sunroof cover,
refer to 54 12 117.
54 12 ... Replacing seal for complete glass slid/tilt sunroof frame
Remove complete glass slide/tilt sunroof (frame),

refer to 54 12 211.
Remove seals (1) and (2) from glass sunroof frame (3).
Clean glued area and stick on new seals.
54 12 117 Replacing seal for glass sliding/tilting sunroof lid
Remove glass slide/tilt sunroof lid,

refer to 54 12 115.
Remove seal (1) from glass slide/tilt sunroof lid (2).
Installation:
Coat guide channel (1) and seal (2) with soapy water.
Begin installation at rear center, with seal (3).
Do not pull seal too tightly in radii (leakage).
54 0 ... Notes on steel and glass slide/tilt sunroofs
(initialization/normalization/learning of characteristic curve)
Note:
Initialization comprises:
Normalization
Learning characteristic curve
The mechanical end positions are recorded and stored during
normalization.
The characteristic curve is learnt immediately after normalization.
When the characteristic curve is learnt, the mechanical closing forces of
the slide/tilt sunroof are recorded and stored for correct operation of the
anti-trapping mechanism.
Note:
An initialization must be performed:
In the event of malfunctions, e.g. no one-touch function, no opening
or no comfort function possible.
After disengagement of the drive unit.
If necessary, after an interruption of the power supply.
After work is carried out on the mechanism of the slide/tilt sunroof.
Note:
The initialization sequence is dependent on the software version of the
slide/tilt sunroof module (in the sunroof drive unit).
If necessary, code slide/tilt sunroof drive unit.
Warning!
There is no anti-trapping protection during initialization.
Normalization:
Press and hold the switch in the ”Lift” direction.

In the event of delayed starting or sudden stopping of the slide/tilt
sunroof, continue pressing the switch in the ”Lift” direction.
After reaching lift end position (A), keep switch pressed for approx.
20 seconds further.
Normalization is completed when the slide/tilt sunroof in lift end
position (A) presses again briefly in the direction of position (B).
Release switch.
Learning characteristic curve:
E38 from 9/98; replacement of drive unit

E39 from 3/98
E46 Compact
E46 Saloon, Touring, Coupé from 09/2001; initial equipment of drive
unit
E46 Saloon, Touring, Coupé; replacement of drive unit
E53 slide/tilt sunroof (not: panoramic glass sunroof):
The curve is learnt manually in the following steps:
Release switch after normalization for max. 5 seconds.
Then hold down the switch in the raising position direction until such
time that the slide/tilt sunroof has returned to the closed position
after a complete opening movement.
This concludes learning of the curve. The switch can now be
released.
Note:
E38 up to 9/98; initial equipment and replacement of drive unit

E39 up to 3/98:
In these cars, the curve is learnt automatically during operation by way of
the module.
After normalization, open and close slide/tilt sunroof fully once by
pressing switch.
In the event of faulty triggering of the anti-trap protection facility in specific
positions, the fault can be rectified by moving over the relevant position
numerous times.
E38 from 9/98; initial equipment of drive unit

E46 Saloon, Touring, Coupé up to 09/2001; initial equipment of drive
unit:
The curve is determined by means of coding.
accident).

All MINI
All other BMWs Yes
All MINI Yes
Warning!
before removing.
Important!
3. Slide clamp back
Installation note:

temperature.
Installation note:
curing)
61 00 ... Battery charging calendar
Battery charging calendar 2016 (PDF file)
Information for the battery charging calendar
61 20 908 Carrying out a voltage interruption of the 12-V battery
Important!
There are two ways to carry out a voltage interruption of the 12-V
battery:
1. Manually by disconnecting the battery earth lead
2. With the diagnosis system
1. Manually: Carry out the following steps:

Switch off and disconnect battery charger
Turn off ignition.
For vehicles with ignition key: Ignition key in neutral position
Vehicles with ID transmitter: Remove ID transmitter from slot
For vehicles with Comfort Access: Secure terminal 30
Disconnect negative battery lead
Reconnect battery earth lead (to ensure bus activity)
Observe a waiting period of 5–10 s
Observe a waiting period of approx. 1 minute
Connect battery earth lead
Connect and switch on battery charger
Switch on ignition.
2. With the diagnosis system:

03 Body
Voltage supply
Activate rest state
Power-down command
61 00 ... Encode/program control unit(s)
Note:
Depending on the vehicle and the equipment, the following flat rate unit
items are available for programming/encoding:
61 00 710
61 00 720
61 00 730
Note:
In order to avoid incorrect programming procedures and fault
messages, it is essential when working with the ISTA/P
programming system always to use the version.
Battery voltage must not drop below 13.0 V during programming.
Only use chargers* recommended by BMW for low voltage vehicle
electrical system.
*Sourcing reference Workshop Equipment Catalogue
programming routine via ISTA/P:
Connect the battery charger to the vehicle.

Connect the programming system with the vehicle.
Determine the action plan.
Accept action plan with the control units to be programmed/encoded
and enabled, if necessary or work through.
Observe the reworking list!
If applicable, connect the workshop system to the vehicle
depending on the rework list, run the brief test and delete the fault
memory.
Note:
A switch to the workshop system may not necessarily be required
with the integration of the service functions and the "Delete fault
memory" function in ISTA/P. Check the rework list accordingly!
The information about programming the workshop system and the
corresponding notes in the user documentation must be observed.
61 00 730 Encode/program control unit
(s) (After vehicle test)
1 â€“ Encode/program control unit(s)
Prerequisite
Replacement of the control unit.
Use the most recent software version to prevent faults during programming/encoding.
The battery voltage must not fall below 13.0 V during programming.
Use only chargers for a low volt-vehicle electrical system that are recommended by BMW.
No high-voltage switch off is required in electric vehicles or hybrid vehicles for programming/encoding.
The high-voltage system will be automatically switched off by the programming system.
Exception:
BMW I01: Note Product and Measures Management Aftersales measure 55176388.

Accept and fully process the measures plan.
If applicable, connect the workshop system to the vehicle, depending on
the reworking list.
Carry out vehicle test.
Wait until programming/encoding has been completed.
Disconnect the programming system from the vehicle.
Disconnect the battery charger from the vehicle.


replacement.
Warning!
damage.
Attention!
agents !
Warning!

Suitable gloves
Apron
Rubber boots
Ear protectors
Safety shoes
Attention!
engine
washes.
tyre valves.
Attention!
Preparation:
Important!
speed.
Operation:
compartment.
Important!
Risk of explosion!
61 13 ... Opening plug housings and removing contacts of different plug
systems

61 0 300
61 0 400
61 1 100
61 1 150
Abbreviations of contacts and what they mean:

ELA Strand seal
D 1.5 / 2.5 / 3.5 Round contacts with 1.5 mm, 2.5 mm or 3.5 mm diameter
MDK Miniature double flat spring contact
JPT Junior Power timer
DFK Double flat spring contacts
Elo Electronic contacts
Elo Power Electronic contacts for heavy load
MQS Micro Quadlock system
MPQ Micro Power Quadlock
MLK Mini laminated contact
SLK Sensor laminated contact
Mcon Multi contact
Important!
The contacts can be changed on ultrasonically welded plugs (1).
Ultrasonically welded plugs (1) must be replaced completely.
Ultrasonic-welded connectors (1) can be identified by the welds (2)
on their longitudinal side.
Note:
Special tools referred to in the repair instructions below are
contained in the following special tool kits:
Release and press-out tool 61 1 150
is replaced from 09/2005 by 61 0 300 (BMW) and 61 0 400
(MINI)
Release and press-out tool 61 1 100 (engine)
Repair instructions for opening plug housings and removing contacts of different plug systems:
Plug system D 1.5/D 2.5:
Circular plugs, 7-, 8-pin, System D 2.5

Circular plugs, 13-pin, System D 2.5
Circular plugs, 4-, 7-, 10-, 12-, 25-pin, System D 1.5/D 2.5
In-line plugs, 15-pin, System D 2.5
In-line plugs, 8-, 12-pin, System D 2.5
Plug system JPT/MDK/DFK:
In-line plugs, 2-pin, System JPT ELA

In-line plugs, 2-pin, System MDK 3plus 2.8
In-line plugs, 4-pin, System DFK ELA
Plug system Elo/Elo-Power:
In-line plugs, 4-, 10-pin, System Elo

In-line plugs, 6- to 50-pin, System Elo
In-line plugs, 3-, 6-pin, System Elo-Power 2.8
Plug system MQS/MPQ:
In-line plugs, 6-, 8-pin, System MQS

In-line plugs, 2-pin, System MPQ 2.8
Control unit plugs, 25-, 35-, 55-, 83-, 88-pin
In-line plugs, 24-pin, Hybrid System MQS/MPQ
Socket housing 42-, 43-pin, Hybrid System MQS / MPQ
Socket housings 2x21-, 2x27-pin, Hybrid System MQS/MPQ, Elo/Elo-Power
Socket housings, 5-, 8-pin, System MQS/MPQ
Socket housing (radio plug), Hybrid System MQS/MPQ
For plug contact systems not listed, refer to Service Information:
SI 2 05 05 217
SI 2 05 06 294
SI 2 03 08 440
SI 2 08 06 312
SI 2 02 08 439
SI 2 01 08 438
61 00 ... Repairing airbag cables
Important!
Only repair those cables which show visible signs of damage. In the event of visible damage,
make sure there is only one cable repair in effect after the repair work. If no visible damage can be
identified, the entire cable must be replaced. When carrying out repairs to the airbag wiring
harness, you must use the spare parts offered in the Electronic Parts Catalogue (EPC).
Safety regulations for handling components of airbag system.

In event of non-visible damage to wiring harness:
Disconnect plug connection on airbag module or on adapter plug. It is absolutely vital to disconnect the
contacts in succession as there is a risk of mixing up (similar parts)! Cut through one cable after the other at an
appropriate position, do not under any circumstances cut through both cables at the same time. Insulate
cables remaining in wiring harness with insulating tape. Now disconnect plug connection on airbag control unit.
Unpin contacts. Cut through one cable after the other at an appropriate position and insulate with insulating
tape, do not under any circumstances cut through both cables at the same time. Pin contacts of repair cable
for airbag control unit in control unit plug, assignment of repair cables is relevant. Lay repair cable in vehicle
parallel to existing airbag lead. Now pin in contacts for airbag control unit or contacts of adapter plug,
assignment of repair cables is relevant. Cut off excess length of repair cable in proximity (visible area) of airbag
module or of adapter plug. Twist open cables. With the butt connectors and heat-shrink tubings in the
Electronic Parts Catalogue (EPC), reconnect the cables with the same cable colours. Twist cables again, open
length (twist) must not exceed 40 mm. Secure interface (heat-shrink tubing) with insulating tape to prevent
cables from twisting open.
Instructions for cutting off, insulating, crimping cables, installing and removing contacts:
Cutting off and insulating cables.
Repairing a plug connection using butt connectors.
Installing and removing contacts.
In event of visible damage:
Expose cable at damaged areas. Cut through one cable after the other at an appropriate position and insulate
cables no longer required in wiring harness with insulating tape, do not under any circumstances cut through
both cables at the same time. Now, depending on the scope of work, unpin contacts either on airbag control
unit/airbag module or on adapter plug. Cut off unpinned cables. Insulate cables remaining in wiring harness with
insulating tape. Now pin in contacts of repair cable, assignment of repair cables is relevant. Lay repair cable in
vehicle parallel to existing airbag lead up to separation point. Cut off excess length of repair cable. Twist open
cables. Connect cables with butt connectors and heat-shrink tubings in Electronic Parts Catalogue (EPC),
assignment of repair cables is relevant. Twist cables again, open length (twist) must not exceed 40 mm.
Secure interface (heat-shrink tubing) with insulating tape to prevent cables from twisting open.
Repairing a plug connection using connectors.
1. Qualification:
controls.
2. Identification:
vehicle!
water foam).
engine is running.
any other work.
and damage.
be replaced.
safety screws.
61 00 ... Safety instructions for handling vehicle battery
Do not allow any battery acid to come into contact with the eyes, the skin or clothing. Therefore wear
protective clothing, gloves and eye protection.
Do not tilt the battery, acid may emerge from the vent hole.
If acid is splashed into the eyes, rinse them immediately for several minutes with clear water. You must then
consult a doctor without delay.
If acid is splashed onto the skin or clothing, neutralise it immediately with a soap solutionand rinse with lots of
water.
Seek medical attention immediately if battery acid is accidentally swallowed.
Strictly no flames, sparks, naked light or smoking!
A highly explosive detonating gas is created when batteries are charged. The rooms where charging is carried
out must therefore always be well ventilated.
Avoid the formation of sparks when handling cables, wiring and electrical devices.
Turn the ignition lock to the 0 position before disconnecting or connecting the battery.
Do not place tools or any similar object on the battery (danger of short circuit and explosion hazard!).
61 13 ... Socket housing (radio connector), Hybrid System MQS/MPQ

61 0 314
Manufactured by AMP: The following contact types without strand

sealing can be fitted in the connector housings:
MQS (Micro Quadlock System)
MPQ, width 2.8 mm (Micro Power Quadlock)
Removing MPQ contacts from radio connector:

Press lock (1) in direction of arrow.
Detach secondary lock (2) from radio plug.
Feed special tool 61 0 314 (61 1 135) past side of contact.

Press special tool 61 0 314 (61 1 135) in direction of arrow.
Pull wire (1) with socket contact out of radio connector (2).
Removing MQS contacts from contact carrier:

Press lock (1) in direction of arrow and pull housing (2) out of radio
connector.
Press lock (1) in direction of arrow. Pull contact carrier (2) out of housing
(3).Note:
When the contact carrier is pulled out, the secondary locks of the socket
contacts are raised.
Note:
Schematic diagram shows the 8‐pin socket housing by way of example.
Hold down retaining hook (1) of socket contact in opening of contact

carrier with a small screwdriver.
Pull wire with socket contact in direction of arrow as far as secondary lock
(2).
Hold down retaining hook in secondary lock (1) again. Pull wire with
socket contact (2) out of contact carrier (3).
Removing MPQ contacts from contact carrier:

Remove contact carrier (1) with MQS contacts from radio connector.
Raise lock (2) on radio connector.
Pull contact carrier (3) out of radio connector.
Pull secondary lock (2) in direction of arrow completely out of contact
carrier (3).
Press special tool 61 0 314 (61 1 135) on inside of contact into contact
carrier (2).
Pull wire with socket contact (1) out of contact carrier (2).
61 13 ... Socket housing 42-, 43-, 46-pin, Hybrid System MQS / MPQ

61 0 312

sealing can be fitted in the socket housings:
Open secondary locks (1) on socket housing.

Press back retaining hook of MQS contacts (2) with special tool 61 0 312
61 1 134 and pull out cable with contact.
Press back retaining hook of MPQ contacts (3) with screwdriver and pull
out cable with contact.
Installation note:
Bend open retaining hook of contacts gently before inserting into
connector housing.
For installation of contacts, observe chamber numbers on reverse side

of socket housing.
61 13 ... Socket housings, 2x21-, 2x27-pin, Hybrid Systems MQS/MPQ, Elo/Elo
Power

Manufactured by Siemens: The following contact types without strand
Elo (electrical contact)
Elo Power 2.8 mm width (electrical contact for heavy loads)
Raise lock (1) on housing (2).

Push contact carrier (3) from rear out of housing.
Note:
The second contact carrier is pushed out in the same way.
Pushing out the contact carrier releases the secondary locks of the
socket contacts.

(2).
Hold down retaining hook in secondary lock (1) again and pull cable with
socket contact (2) completely out of contact carrier (3).
61 13 ... Socket housings, 5-pin, 8-pin, System MQS/MPQ

Socket housing, 5-pin (Hybrid System MQS/MPQ)

Raise fastener (1) over retaining lug (2) and pull off from contact
carrier (3).
Socket housing, 8-pin (MQS):

carrier (3).
Hold down retaining hook (1) of contact and pull cable with contact as far
as secondary lock (2).
contact (2) completely out of contact carrier (3).
61 13 ... Treating cables and fibre-optic cables

61 1 190
61 4 320
Note:
Special tools referred to in the repair instructions below are contained in
the following special tool kits:
Repair range for vehicle electrical system SI 2 04 07 341

Crimping set with tool for fibre-optic cables, Micro Power 61 4 320
Quadlock (MPQ), Micro Quadlock System (MQS)
contacts and universal crimping head
Insulation displacement tool for ribbon cable 61 1 190
Subject of repair instructions
Special tools for wiring harness repairs

Cutting cables to length and strip insulation
Crimping stop parts (contacts)
Butt connector for repairing a plug connection
Fan connector for retrofitting/repairs
Aerial elbow plug on radio receiver
Cutting to length and stripping insulation from optical fibres
Crimping optical fibres
Insulation displacement connector for repairing ribbon cables
61 13 ... Unlocking and disconnecting different plug connections
Note:
The document describes unlocking and disconnecting different types of
plug connections.
Differences in the details of the size and shape of the plug connections
are possible.
1.
Press lock and open release clip in direction of arrow.
Disconnect plug connection.
2.
3.
Open release clip in direction of arrow and disconnect plug connection in
direction of arrow.
4.
Press lock and disconnect plug connection in direction of arrow.
5.
6.
7.
8.
9.
10.
Press the lock and detach plug connection.
11.
12.
Press the lock on both sides and detach plug connection.
13.
14.
15.
16.
Pull out lock and press.
17.
18.
19.
20.
Plug connection, e.g. on the power distribution box:
Press into the opening (2) using a suitable tool (1).
Pull off plug connection (3) upwards.
21.
Lift lock (1) with a suitable tool.
22.
Vibration resistant high power engine contacts:
Caution!
For this connector type, increased forces come into play when
disconnecting and closing.
Disconnect:
Pull out lock (1) downward in direction of arrow first.
Then press lock (1) down in direction of arrow and pull off connector.
23.
Close:
A. Press the connector (1) down at the points indicated by the arrow until it reaches the end position
B. Do not press the connector (1) further than the lock
C. Connector (1) is in the end position, but lock (2) is not yet locked
D. Press lock (2) down in the direction of the arrow until the tip of lock (2) is visible at point (3)
Unlock / lock front light combination plug connection & replace housing after damage:
24.
Press in locking lever at both sides until the lever is unlocked and can be
moved.
Move lever upwards until it latches into place in the end position.
Once the lever is locked in the end position, remove plug connection
upwards.
Unlock socket housing by lifting up each of the locking tabs.

Slide out after unlocking the socket housing.
Slide in socket housing up to limit position.
Lock socket housing into place in end position.
Sliding in up to limit position.

Activate plug-inn procedure by moving lever downwards.
IMPORTANT: the latch mechanism on both sides only works for a
completed plug-in procedure.
25.
Rosenberger D4S20G-400A5-Y
Press to unlock on both sides.
26.
Pin housing, 15-pinMLK1
A & B. To avoid any damage to individual connectors, the given
connector assembly consisting of several individual connectors (1)
& (2) must be released before disconnecting the plug connection.
C: released connector assembly
Disconnecting connector assembly:
Release retaining hooks (1) in direction of arrow (detail image shows
retaining hooks of individual connector).
Release connector (2) in direction of arrow from connector (1).
27.
Airbag ignition circuit connector
Warning!
Note the safety information for working on vehicles with airbag
systems prior to disconnecting the plug connection.
Pull the cap (1) in the direction of the arrow to unlock

28.
Connector e.g. on front and rear lighting unit
Open safety catch (1) in direction of arrow using appropriate tool.
Push safety catch (2) in direction of arrow and disconnect plug
connection.
29.
Plug, e.g. in airbag ignition circuits
Press the lock (1) and pull out the connector (2) up to initial engagement
position.
Pull off connector (2).
and hybrid vehicles
Attention!
connections:
connection.

the arrow.
Attention!

Note:

Attention!

Warning!
must be replaced!


housing.
Attention!

Attention!
the risk of danger.

Press lock (1).

the KLE:
Attention!
under the lock (2).
Attention!
connector housing.

Attention!
connector housing.

line):
of arrow (2).
Attention!
connector housing.
61 13 ... Special tools for wiring harness repairs

61 0 300
61 0 400
61 1 100
61 4 320
61 0 200
61 0 210
61 0 220
61 0 230
61 0 240
Repair range, vehicle electrical system:

Single parts for wiring harness repairs*
* Sourcing reference: BMW Parts Department
Note:
Refer to Service Information:
SI 2 04 07 341
Release and press-out tool:

Special tool61 0 300
Special tool 61 0 400 (MINI N12/N14)
Special tool 61 1 100 (engine)
Handling:
Notes for opening contacts and locks of different connector contact
systems
Cutting to length and stripping insulation from cables:

Wire stripper MultiStrip10*
Handling:
Crimping stop parts (small contacts) and butt connectors:
1. Tool without crimping head
2. Crimping head (stripping insulation and cutting fibre-optic
cables to length)
3. Crimping head (crimping fibre-optic cable contacts)
4. Crimping head (crimping MQS contacts)
5. Crimping head (crimping MPQ contacts)
6. Replacement blade (face-cutting fibre-optic cables)
7. Replacement blade with tool (insulation stripping unit)
8. Universal crimping head (SI 2 04 06 293)
Crimping stop parts (large contacts) and butt connectors:

Special tool 61 0 200 (crimping set)
Special tool 61 0 210 (matrix set SLK 8)
Special tool 61 0 220 (matrix set SLK 2.8)
Special tool 61 0 230 (matrix set MAK 8 / DFK4)
Special tool 61 0 240 (butt connector 4.0 - 6.0 mm²)
Handling:
SI 2 02 05 194
SI 2 07 05 233


replacement.
systems

61 0 300
61 0 400
61 1 100
61 1 150

ELA Strand seal
Mcon Multi contact
Important!
Note:
(MINI)




SI 2 05 05 217
SI 2 05 06 294
SI 2 03 08 440
SI 2 08 06 312
SI 2 02 08 439
SI 2 01 08 438
Note:
plug connections.
are possible.
1.
2.
3.
direction of arrow.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Caution!
Disconnect:
23.
Close:
24.
moved.
upwards.


25.
26.
27.
Warning!

28.
connection.
29.
position.
61 13 ... Antenna elbow plug on radio receiver
Important!
This repair solution is only possible
up to model year 10/ 2000.
Replace entire antenna cable on affected vehicles.
Refer to Spare Parts Catalogue.
Cut off faulty antenna angle plug directly after strain relief.
Carefully and with precision, strip insulation from antenna cable as
illustrated (lengths given in mm).
Brush shield (copper braid) towards rear.
Important!
There must be no more copper wire protruding in the direction of the
inner conductor on the inner conductor insulation (risk of short
circuits).
Create a loop on inner conductor.
Important!
Cover soldering area extensively in center console all round radio
aperture.
Avoid blobs of melted solder in inside area.
Tin-plate center connection on antenna angle plug and stripped inner

conductor.
Solder inner conductor on center connection with a small soldering iron
(max. 50 watts) and matching soldering tip (1).
Gently push insulation forward to soldering point and pay attention to
correct position of loop.
Note:
The loop must not under any circumstances come into contact with the
metal parts of the antenna plug.
Special tool 61 9 041 (hand pliers) in conjunction with special tool
61 9 044 (matrix) is used to crimp antenna angle plug.Refer to repair
instructions:
Unlock special tool 61 9 041:

Squeeze grips (1) lightly and push unlocking lever (2) in direction of
arrow.
OR:
Compress handles as far as they will go, tool unlocks automatically.
Place antenna angle plug with cable guide and strain relief in matrix (1).
Compress special tool 61 9 041 as far as it will go.

Special tool 61 9 041 unlocks automatically.
Remove antenna angle plug with antenna cable from special tool
61 9 044.
61 13 ... Butt connector for repairing a plug connection

61 0 300
61 9 040
Important!
1. Identify cause of damage (e.g. sharp-edged body
components, faulty electrical loads, jammed mechanisms,
corrosion caused by ingress of water, etc.).
2. Read out fault memory
3. Eliminate cause of damage.
4. Disconnect battery negative terminal
5. Make sure that no safety-related system according to circuit
diagram (e.g. antilock braking system, active rear-axle
kinematics, airbags, etc.) are influenced. Otherwise replace
faulty wiring harness or use repair cable (sourcing reference:
BMW Parts Department)
6. Carry out function test and read out fault memories again
7. Eliminate new faults if applicable and clear fault memories
Note:
The repair range IV for vehicle electrical system contained the required
special tools and individual parts for retrofitting and repair work with the
aid of fan connectors.
The case can no longer be ordered. Order individual parts for wiring
harness repair through BMW Parts Department.
SI 02 04 07 341
Special tools:
Choose repair kit.

Example: Repair kit, circular connector system D 2.5.
Remove following parts:
(1) Pre-packaged end of cable with requisite wire cross-section
(2) Crimp connector for selected wire cross-section
(3) Shrink-fit hose
Open secondary lock on housing.

Mark damaged contact (4) with socket number of housing and press it
out of housing using appropriate special tool contained in special tool set
61 0 300 ).
See repair instructions
Opening plug housings and removing contacts of different plug systems
Important!
Check maximum length of repair cable
If more than one wire is to be repaired, the individual interfaces
must be offset so that the wiring harness is not too thick at the
repaired point.
Adhere to following procedure:

Cut off wire with faulty contact at point which is easily accessible
Strip insulation from end of wire at wiring harness end
Cut preassembled wire end to length and strip insulation
Refer also to repair instruction:
Cutting to length and stripping insulation from cables
Crimp butt connector on preassembled wire end.See repair instructions

Crimping on stop parts
Push shrink-fit hose (8) onto free wire end.
Crimp unused wire end to butt connector.
Pull shrink-on sleeve over butt connector.
Important!
Do not burn shrink-on sleeve.
With hot air blower, shrink the shrink-on sleeve on both sides (9) of
shrink-fit hose until glue emerges uniformly all round.
Insert contact in housing.
Close secondary lock on housing.
61 13 ... Circular connector, 13-pin, system D2.5

61 0 303
Pull off rubber grommet (1).

Carefully pull out lock (2) in direction of arrow.
Move lower section of connector (3) in direction of arrow until retaining

lugs (4) snap into release groove (5).
With special tool 61 0 303 , press down retaining lugs (6) of

corresponding contact and pull out cable.
61 13 ... Circular connector, 20-pin, system D2.5

61 0 303
Carefully press back retaining tabs (1) of internal connector (2).
Turn internal connector (2) until retaining lugs (1) snap into release
groove (3).
With special tool 61 0 303 press down retaining hook (4) of

corresponding contact and pull out cable.
61 13 ... Circular connector, 7-pin, 8-pin, system D2.5

61 0 303
Carefully pull off rubber grommet (1).

Carefully press back retaining tabs (2) of internal connector (3).
Slide internal connector (3) in direction of arrow until retaining tabs (2)
lock into locking groove (4).
Use special tool 61 0 303 (61 1 132) to press back retaining hook (5) of
corresponding contact and pull out cable with contact.
61 13 ... Circular plugs, 4-, 7-, 10- 12-, 25-pin, System D1.5/D2.5

61 0 303
Insert special tool with suitable connection side in connector and twist
approx. 3° anticlockwise.
The connector is locked down if retaining lug (3) is located in locking

groove (2).
1. Unlocking groove
2. Locking groove
3. Retaining lug
With special tool 61 0 303 press back retaining hook(4) of corresponding

contact and pull out cable with contact.
61 13 ... Connector housing, LCC contact (load current contact)

61 0 317
Socket housing:
Press lock (1) with suitable tool (2) in direction of arrow out of socket
housing (3).
Pull lock (1) out of socket housing (2).
Insert special tool 61 0 317 into socket housing (1) and pull out wiring
with LCC contact (2) in direction of arrow.
Pin housing:
Unlock locking slide (1) of pin housing (2) with suitable tool (3) in direction
of arrow.
Insert special tool 61 0 317 into pin housing (1) and pull out wiring with
LCC contact (2) in direction of arrow.
61 13 ... Control unit plugs, 25-, 35-, 55-, 83-, 88-pin

61 0 312
61 0 314
61 0 315
61 0 323
Release screws (1).

Lever out pin sensor (2) with gasket (3) in direction of arrow.
Remove gasket (3).

Pull out housing lock (4) in direction of arrow and unlock.
Press down retaining hook (5) of corresponding contact and pull out
cable with contact.
Special tool 61 0 312 (61 1 134) for mini flat spring contacts.
Special tool 61 0 314 (61 1 135) for mini flat spring contacts.
Special tool 61 0 315 (61 1 151) for double flat spring contacts (dual
retaining hooks).
Special tool 61 0 323 (61 1 152) for double flat spring contacts (special
retaining hook).
61 13 ... Crimping annular contacts

61 4 320
Crimping annular contacts:

Handling:
SI 2 04 06 2939
61 13 ... Crimping Micro Power Quadlock contacts (MPQ)

61 4 320
To crimp MPQ contacts, use hand pliers 61 4 321 (1) in conjunction with
crimping head 61 4 325 (2) from crimping set 61 4 320 .Note:
Hand pliers (1) open automatically until limit position when handles are
pressed together.
Open hand pliers (1).

Note:
Place contact (2) with utmost care in designated nest (observe line
cross-section) in crimping head (3). Make sure it is exactly positioned.
Place MPQ contact (2) in crimping head (3).

Close hand pliers (1) one notch.
Note:
Follow procedure for cutting and stripping insulation from cables.
Insert stripped cable (2).

Close hand pliers (1) fully.
Open hand pliers (1) and remove cable (2).
Important!
Check contact for correct crimping.
61 13 ... Crimping Micro Quadlock System contacts (MQS)

61 4 320
To crimp MPQ contacts, use hand pliers 61 4 321 (1) in conjunction with
pressed together.

Fold up contact carrier (2).
Insert MQS contact (3) in contact carrier (2).
Fold back contact carrier (2).
Note:
Close hand pliers (1) one notch.

Insert stripped cable (2).
Open contact carrier (2) gently and carefully remove MQS contact.
Important!
Check contact for correct crimping.
61 13 ... Crimping optical fibres

61 4 320
To crimp optical fibres, use hand pliers 61 4 321 (1) in conjunction with
pressed together.
Move contact guide by means of stop lever (1) into corresponding

position (pin contact or jack).

Place pin contact or jack (1) in crimping head and secure with locking
lever (3).
Note:
Follow procedure for cutting and stripping insulation from optical fibres.
Insert stripped optical fibre(1) until limit position into pin contact or
jack (2).
Open hand pliers (3) and locking lever (4).
Remove optical fibre (1).
Important!
Make sure optical fibre is correctly seated in jack.
Right (A)
End of optical fibre (1) must be flush with tip of pin contact (2).
Wrong (B)
End of optical fibre (1) is not flush with tip of pin contact (2).
61 13 ... Crimping stop parts

12 1 080
12 1 081
12 1 083
Spare parts for in-car electronics (housing and contacts):

SI 2 04 07 341
1. Crimping butt connectors and contact sleeves for comb

connectors up to 2.5 mm
SI 2 04 06 293
2. Crimping butt connectors and contact sleeves for comb

connectors larger than 2.5 mm 2
SI 2 02 05 194
SI 2 07 05 233
3. Crimping contact sleeves for 4 mm2 comb connectors and ignition

cable contacts
Use special tool kit 12 1 080 to attach ignition cable contacts and crimp
4 mm2 contact sleeves for comb connectors.
12 1 081 (hand pliers)
12 1 083 (nest)
Special tools for wiring harness repairs.
Release special tool 12 1 081 :

Squeeze grips (1) lightly and push release lever (2) in direction of arrow.
Or:
Compress handles until limit position, hand pliers unlock automatically.
Place 4 mm2 contact sleeve in nest with anti-twist safeguard (1) as far as
possible.
Preload contact by squeezing matrix in crimping tool. Grip contact (1)

firmly only, do not crimp.
Note:
Insert stripped end of wire (7) in the contact. Ensure insulation and
stripped wire end are correctly laid in contact.
Compress crimping tool to limit position.
Crimping tool unlocks automatically.
Take contact out of crimping tool.
4. Checking crimping
Check insulation crimping (8) and wire crimp (9) against following
illustrations to ensure crimps are correctly located.
Note:
Illustration shows butt connectors and contact sleeves for comb
connectors knocked on one side. The crimping procedure is identical
here.
Correct crimping:
Visible conductor end (10).
Visible insulation end (11).
Incorrect crimping:
Conductor end (10) inserted too far.
Insulation end (11) in wire crimp.
If necessary, repeat crimping with a new contact.
Incorrect crimping:
Conductor end (10) not visible.
Insulation end (11) not visible.
If necessary, repeat crimping with a new contact.
61 13 ... Cutting off, stripping insulation and cutting optical fibres to length

61 4 321
61 4 329
61 4 320
61 4 323
The hand pliers 61 4 321 (1) in connection with the crimping

head 61 4 329 (2) from crimp kit 61 4 320 are used for cutting, strip
insulation and cutting optical fibres to size.Note:
pressed together.
Cutting optical fibre

Place optical fibre (2) in cutting device (3).
Close pliers (1) and remove optical fibre (2).
Stripping insulation from optical fibre

Open lever (2) in direction of arrow.
Push the optical fibre (1) into the strip insulation equipment (2) until it is
flush in this area (3).
Close the operating lever (5) in the direction of the arrow.
Open hand pliers (4) by one tooth notch.
Re-open the operating lever (5) against the direction of the arrow and
remove the optical fibre (1).
Cutting optical fibre to length

Push the optical fibre (1) into the cutting equipment (2) until the insulation
of the optical fibre (1) comes into contact with the clamping fixture.
Close hand pliers (3) fully and keep closed.
Crimp optical fibre

The hand pliers 61 4 321 (1) in connection with the crimping
head 61 4 323 (2) from crimping kit 61 4 320 are used for crimping the
optical fibres to size.
Note:
pressed together.
Move contact guide by means of stop lever (1) into corresponding

position (pin contact or jack).
Place pin contact or jack (1) in crimping head and secure with locking
lever (3).
Insert stripped optical fibre(1) until limit position into pin contact or
jack (2).
Open hand pliers (3) and locking lever (4).
Caution!
Make sure optical fibre is correctly seated in jack.
Right (A)
End of optical fibre (1) must be flush with tip of pin contact (2).
Wrong (B)
End of optical fibre (1) is not flush with tip of pin contact (2).
61 13 ... Cutting to length and stripping insulation from cables
For cutting cables to length and stripping insulation, refer to Service

Information:
SI 2 07 11 721
Stripped length:
Wire cross-section (mm2) Stripped length (mm)

0,35 ... 0,50 4,0
0,75 ... 1,00 4,5
1,00 ... 2,50 5,0
61 13 ... Fuse holder
Remove appropriate fuse from fuse holder (1).

Note:
Identify the position when removing fuses.
Pull sliding lock (2) out of fuse holder (1) completely.
With special tool 61 1 136 or 61 1 137 (pressing-off tool), press back

retaining hooks (3) of appropriate contact and pull out cable.
61 13 ... In-line connectors, 24-/44-pin, Hybrid System MQS/MPQ

Socket housing:
Press locks (1) on protective cap (2) upwards on both sides.
Detach protective cap from contact carrier (3).
Note:
Detaching the protective cap releases the secondary locks of the socket
contacts.

(2).
Pin housing:
Press locks (1) on protective cap (2) upwards on both sides.
Detach protective cap from housing carrier (3).
Note:
Detaching the protective cap releases the secondary locks of the pin
contacts in the contact carriers.
Pull contact carrier (1) out of housing carrier (2).

The pin contacts are pulled out of a contact carrier as described under
”Socket housing”.
61 13 ... In-line connectors, 30-pin, Hybrid System MQS/MPQ

Socket housing:
Push contact carrier (3) out of housing (2).
Note:
socket contacts.

(2).
Pin housing:
Contacts 1 ... 13 and 19 ... 27:
Raise locking slide (1) on both sides (2) of housing and detach.
Note:
Detaching the locking slide releases the secondary locks of the pin
contacts.
Contacts 14 ... 18 and 28 ... 30:

Pull slide (1) outwards completely.
Raise lock (2) on housing.
Pull contact carrier (3) out of housing.
Note:
Pulling out the contact carrier releases the secondary locks of the pin
contacts.
The pin contacts are pulled out of a contact carrier as described under
”Socket housing”.
61 13 ... In-line connectors, 30-pin, System D2.5

61 0 303
Carefully pull external connector (1) in area of retaining lugs (2) apart
slightly.
Pull internal connector (3) until limit position in direction of arrow.

61 13 ... In-line plugs, 2-pin, System JPT ELA

61 0 316
Press lock (1) in direction of arrow and slide connector forward.
Press lock (1) downward and slide out to one side.
With special tool 61 0 316 (61 1 136), unlock contact and pull out cable
with contact (1) towards rear.
61 13 ... In-line plugs, 2-pin, System MDK 3 plus 2.8

61 0 316
Unlock lock (1) on outside at retaining hook and slide out lock (1) to side.
61 13 ... In-line plugs, 20-pin, System D2.5

61 0 303
Pull locking slide (1) out of connector (2).
With special tool 61 0 303 , press down retaining hook (3) of

61 13 ... In-line plugs, 4-pin, System DFK ELA

61 0 316
Press retaining hook in direction of arrow and remove lock (1).
Installation notes:
If necessary, side lock must also be unlocked with screwdriver.
61 13 ... In-line plugs, 6- to 50-pin, System Elo
Open lock.
Detach cable strap.
Installation note:
Cable strap must be reinstalled.
Detach catch (1) from connector housing (2).
Press out contact carrier (3) with wiring harness (4) through opening (5).
Hold down retaining hook (6) of defective contact and pull cable and
contact up to secondary lock (8).
Hold down retaining hook once again in secondary lock (8) and pull cable
and contact completely out of contact carrier.
61 13 ... Inline connectors, 15-pin, System D2.5

61 0 303
Carefully pull external connector (1) in area of retaining lugs (2) apart
slightly.
Pull internal connector (3) until limit position in direction of arrow.

61 13 ... Inline connectors, 6-, 8-pin, System MQS
Press lock (1) in direction of arrow and slide connector forward.
Press locking hook (2) downward and slide lock (1) out.
Press down retaining hook (1) with screwdriver and pull out cable with
contact towards rear.
61 13 ... Inline plugs, 2-pin, System MPQ 2.8
Press catch on outside in direction of arrow and remove towards top.
Press down retaining hook (1) with screwdriver and pull out cable and
contact (2) towards rear.
61 13 ... Inline plugs, 3-, 6-pin, System Elo-Power 2.8
Press locking hook (1) in direction of arrow and disengage. Then unlock
locking hook (2) and remove lock.
Press down retaining hook with screwdriver (1) and pull out cable with
contact towards rear.
61 13 ... Inline plugs, 4-, 10-pin, System Elo
Detach fastener (1) from contact carrier (2).
Hold down retaining hook (3) of defective contact and pull cable and
contact up to secondary lock (6).
Hold down retaining hook once again in secondary lock and pull cable
and contact completely out of contact carrier.
61 13 ... Inline plugs, 8-, 12-pin, System D2.5

61 0 303
Move upper section of connector (1) and lower section of connector (2)
against each other in direction of arrow.
With special tool 61 0 303 , press down retaining hook (3) of

61 13 ... Installing comb connector for retrofitting/repairs

61 9 040
61 9 041
61 9 042
Note:
The repair range IV for vehicle electrical system contained the required
special tools and individual parts for retrofitting and repair work with the
aid of fan connectors.
The case can no longer be ordered. Order individual parts for wiring
harness repair through BMW Parts Department.
SI 02 04 07 341
Special tools:
Choose contact sleeve (up to 4 mm2) in accordance with wire cross-

section.
Alternatively:
Choose contact sleeves (up to 2.5 mm 2) for comb connectors.
Cut through wire loop in wiring harness at established point.
Strip insulation from both wire ends.
Cutting to length and stripping insulation from cables
Crimp contact sleeves on both wire ends.See repair instructions

Crimping on stop parts
Note:
If using repair kit for contact sleeves, refer to repair instructions:
Butt connector for repairing a plug connection.
Crimp connecting cable for retrofitting likewise with contact sleeve.
Cut required number of poles to length for comb connectors.

Special tool 61 9 041 (hand pliers) in conjunction with 61 9 042 (matrix)
are used for pushing contact sleeves onto comb connectors.See repair
instructions
Special tools for wiring harness repairs.
Unlock special tool 61 9 041 :

Squeeze grips (1) lightly and push release lever (2) in direction of arrow.
Or:
Compress handles until limit position, hand pliers unlock automatically.
Insert prepared comb connectors (3) in special tool 61 9 041 / 61 9 042 .
Attach wire with contact sleeve to comb connector.

Press hand pliers together and slide on contact sleeve until limit position.
Important!
Once contact sleeves have been pushed on, they should not be
detached again from the comb connector or reused.
Push on further contact sleeves for potential branching.
Installation in wet area (engine compartment, wheel arch):

Apply sealing compound on both sides and press into contacts (1).
Fit heat-shrink tubing and heat up with hot air blower (2) (approx. 250 °C).
Note:
Ensure that comb connector has sufficient contact surface on attachment
point.
Do not heat-shrink tubing on edges of comb connector too strongly, risk
of cracking.
Allow heat-shrink tubing to cool down until hand-warm. Then press

sealing material again into contacts and onto edges of comb connector.
If necessary, carefully heat-shrink tubing again.
Installation in dry area (interior, luggage compartment):

Slide assembled comb connector into insulation housing until it locks into
place.
61 13 ... Main relay connector for DME
Open locking clamp (1) for the corresponding cable.

retaining hooks (2) of appropriate contact and pull out cable with contact.
systems

61 0 300
61 0 400
61 1 100
61 1 150

ELA Strand seal
Mcon Multi contact
Important!
Note:
(MINI)




SI 2 05 05 217
SI 2 05 06 294
SI 2 03 08 440
SI 2 08 06 312
SI 2 02 08 439
SI 2 01 08 438
61 13 ... Relay carrier
Place special tool 61 1 153 against relay carrier (1) and carefully pull in
direction of arrow until the locking tabs (2) of the relay carrier are raised
up.
Pull relay carrier (2) in direction of arrow into the first catch (3).
Press down arrester hook (4) of corresponding contact and pull out the
cable with contact.
With special tool 61 1 136 or 61 1 137 (press out) press out dual spring
contacts.
Important!

61 13 ... Repairing ribbon cables

61 1 190
Place ribbon cables (1) in connector housing (2) and close cover (3).
Place connector housing (1) in pliers (2) 61 1 190 .

Close pliers (2).
61 13 ... Socket housing (radio connector), Hybrid System MQS/MPQ

61 0 314

Removing MPQ contacts from radio connector:

Detach secondary lock (2) from radio plug.
Feed special tool 61 0 314 (61 1 135) past side of contact.

Press special tool 61 0 314 (61 1 135) in direction of arrow.
Pull wire (1) with socket contact out of radio connector (2).
Removing MQS contacts from contact carrier:

Press lock (1) in direction of arrow and pull housing (2) out of radio
connector.
Press lock (1) in direction of arrow. Pull contact carrier (2) out of housing
(3).Note:
When the contact carrier is pulled out, the secondary locks of the socket
contacts are raised.
Note:
Schematic diagram shows the 8‐pin socket housing by way of example.

(2).
Hold down retaining hook in secondary lock (1) again. Pull wire with
socket contact (2) out of contact carrier (3).
Removing MPQ contacts from contact carrier:

Remove contact carrier (1) with MQS contacts from radio connector.
Raise lock (2) on radio connector.
Pull contact carrier (3) out of radio connector.
Pull secondary lock (2) in direction of arrow completely out of contact
carrier (3).
Press special tool 61 0 314 (61 1 135) on inside of contact into contact
carrier (2).
Pull wire with socket contact (1) out of contact carrier (2).
61 13 ... Socket housing 42-, 43-, 46-pin, Hybrid System MQS / MPQ

61 0 312

Open secondary locks (1) on socket housing.

Press back retaining hook of MQS contacts (2) with special tool 61 0 312
61 1 134 and pull out cable with contact.
Press back retaining hook of MPQ contacts (3) with screwdriver and pull
out cable with contact.
Installation note:
Bend open retaining hook of contacts gently before inserting into
connector housing.
For installation of contacts, observe chamber numbers on reverse side

of socket housing.
61 13 ... Socket housings, 2x21-, 2x27-pin, Hybrid Systems MQS/MPQ, Elo/Elo
Power

Manufactured by Siemens: The following contact types without strand
Elo (electrical contact)

Push contact carrier (3) from rear out of housing.
Note:
The second contact carrier is pushed out in the same way.
socket contacts.

(2).
61 13 ... Socket housings, 5-pin, 8-pin, System MQS/MPQ

Socket housing, 5-pin (Hybrid System MQS/MPQ)

carrier (3).
Socket housing, 8-pin (MQS):

carrier (3).
Hold down retaining hook (1) of contact and pull cable with contact as far
as secondary lock (2).
contact (2) completely out of contact carrier (3).
61 13 ... Socket of tab connector housings
Unlock hooks (1) with special tool 61 1 360 and push plug housing out of
the socket.

12 1 080
61 0 200
61 0 210
61 0 220
61 0 230
61 0 300
61 0 400
61 1 190
61 4 320
61 9 041
61 9 044

SI 2 04 07 341

Handling:
Opening plug housings and removing contacts of different plug
systems
SI 2 05 05 217
SI 2 05 06 294
SI 2 08 06 312

Handling:
Crimping stop parts (small contacts):
cables to length)
Crimping stop parts (large contacts):

Special tool 61 0 210 (matrix set
Handling:
SI 2 02 05 194
SI 2 07 05 233
Crimping antenna elbow plugs:

Special tool 61 9 041 (pliers)
Special tool 61 9 044 (matrix)
Handling:
Antenna elbow plug on radio receiver
Repair kit for ignition cables and for crimping fan connector
receptacles 4 mm 2:
Handling:
Repairing ribbon cables:
Handling:
Repairing ribbon cables

61 0 300
61 0 400
61 1 100
61 4 320
61 0 200
61 0 210
61 0 220
61 0 230
61 0 240

Single parts for wiring harness repairs*
* Sourcing reference: BMW Parts Department
Note:
SI 2 04 07 341

Special tool 61 1 100 (engine)
Handling:
Notes for opening contacts and locks of different connector contact
systems

Wire stripper MultiStrip10*
Handling:
Crimping stop parts (small contacts) and butt connectors:
cables to length)
Crimping stop parts (large contacts) and butt connectors:

Special tool 61 0 210 (matrix set SLK 8)
Special tool 61 0 240 (butt connector 4.0 - 6.0 mm²)
Handling:
SI 2 02 05 194
SI 2 07 05 233
61 13 ... Treating cables and fibre-optic cables

61 1 190
61 4 320
Note:
Special tools referred to in the repair instructions below are contained in
the following special tool kits:
Repair range for vehicle electrical system SI 2 04 07 341

Crimping set with tool for fibre-optic cables, Micro Power 61 4 320
Quadlock (MPQ), Micro Quadlock System (MQS)
contacts and universal crimping head
Insulation displacement tool for ribbon cable 61 1 190
Subject of repair instructions

Butt connector for repairing a plug connection
Fan connector for retrofitting/repairs
Aerial elbow plug on radio receiver
Cutting to length and stripping insulation from optical fibres
Crimping optical fibres
Insulation displacement connector for repairing ribbon cables
Note:
plug connections.
are possible.
1.
2.
3.
direction of arrow.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Caution!
Disconnect:
23.
Close:
24.
moved.
upwards.


25.
26.
27.
Warning!

28.
connection.
29.
position.
and hybrid vehicles
Attention!
connections:
connection.

the arrow.
Attention!

Note:

Attention!

Warning!
must be replaced!


housing.
Attention!

Attention!
the risk of danger.

Press lock (1).

the KLE:
Attention!
under the lock (2).
Attention!
connector housing.

Attention!
connector housing.

line):
of arrow (2).
Attention!
connector housing.
Important!
battery:

Turn off ignition.
Switch on ignition.

03 Body
Voltage supply
Activate rest state
Power-down command


replacement.
Note:
control units.
Attention!
cover the wires.

Attention!
For example:

battery.
Attention!

Note:
bonnet is open.
Prerequisite:
Note:
running.
Trickle charging
Attention!
61 20 ... Notes on AGM battery
Introduction
In September 2002, the first so-called VRLA batteries, better known as AGM batteries came into use. (VRLA
stands for Valve Regulated Lead Acid, i.e. lead-acid battery with pressure relief valve; AGM stands for
Absorbent Glass Mat, i.e. absorbent glass-fibre fleece).
The constantly increasing energy demand of modern vehicle electrical systems calls for ever more powerful
battery solutions. A modern luxury-class vehicle has some 100 actuator motors that have to be fed with
electrical current. Added to these are safety, environmental and comfort elements which are increasingly
becoming standard features, such as e.g. Antilock Brake System (ABS), Dynamic Stability Control (DSC),
steering assistance (EPS), electronic chassis and suspension control, air conditioning and navigation system.
The somewhat higher price compared with a battery of similar size is fully balanced by the following benefits:
100 % freedom from maintenance
5 50 % capacity limit
held freely in the battery housing. Rather, 100% of the sulphuric acid is bound into the mats of the glass-fibre
fleece (separators). For this reason, no battery acid can escape if the battery housing is damaged. In addition,
the AGM battery is sealed to be airtight. This is possible because the gases are converted back into water by
the permeability of the separators.
The AGM battery has a black housing and the so-called "Magic Eye" is missing.

1 Positive grille with silver alloy 2 Positive plate
3 Negative grille 4 Negative plate
5 Separator made of glass-fibre fleece 6 Set of positive plates

7 Set of negative plates 8 Block of plates
9 Block box with base strips
Construction
The AGM battery differs from the conventional lead calcium battery as follows:
larger plates: Larger plates allow a 25% larger power density.
Separators made of glass-fibre fleece: These can cause an up to 3-times higher cycle stability to be
reached. This improves the cold starting capability, the power consumption and service life.
Airtight housing with pressure relief valve (please refer to ”How it works”):
The inspection plugs are sealed and can not be opened.
Battery acid bound in glass-fibre fleece: Battery acid is not found free in the housing as before, but is
rather bound 100% in the glass-fibre fleece. This gives increased security against the acid escaping and
thus reduces the environmental risk.
How it works
The AGM battery differs from conventional batteries in its non-polluting and substance-retaining behaviour
during charging.
When a battery is charged, the electrolysis process emits the gases oxygen and hydrogen.
In a conventional wet lead calcium battery, the two gases hydrogen and oxygen are dissipated into the
atmosphere.
In an AGM battery, the two gases are converted back into water: The oxygen which is created at the
positive electrode during charging passes through the permeable glass fibre fleece to the negative
electrode. At the negative electrode the oxygen reacts with the arriving hydrogen ions in the electrolyte
to form water (oxygen cycle).
In this manner, the gas and thus also the electrolyte are not lost.
Only in the event of an excessively heavy build-up of gas, i.e. excessively high pressure build-up (20 to
200 mbar), does the pressure relief valve discharge the gas. In this process, the pressure relief valve does
not allow any oxygen in the air to enter. Because the pressure in the battery is regulated by a valve, the AGM
battery is also known as the VRLA battery (valve-regulated lead acid).
It is necessary when handling an AGM battery to observe some particular points pertaining to battery changing
and installation location.
Charging
Warning! Do not charge the AGM battery with > 14.8 V. Do not use rapid-charging programs!
When charging removed batteries (so-called stand‐alone batteries), do not exceed the maximum
charging voltage of 14.8 V at room temperature. Also, for charging via the external start connection
point, the maximum charging voltage of 14.8 V at room temperature must not be exceeded. The
battery can be damaged even if the AGM battery is only briefly charged with a charging voltage higher
than 14.8 V. A charging voltage of more than 14.8 V is usually used in quick-charging routines.
Installation location
Warning! Do not install the AGM battery in the engine compartment.
The AGM battery must not be installed in the engine compartment on account of the high spatial
temperature differences, otherwise its service life will be significantly shortened.
Housing
Warning! Do not open AGM batteries.
On no account may AGM batteries be opened, as the ingress of oxygen from the atmosphere would
cause the battery to lose its chemical balance, rendering it unserviceable.
Preparation:
Important!
speed.
Operation:
compartment.
Important!
Risk of explosion!
Important!

1. Qualification:
controls.
2. Identification:
vehicle!
water foam).
engine is running.
any other work.
and damage.
be replaced.
safety screws.
61 00 ... Safety instructions for handling vehicle battery
Do not allow any battery acid to come into contact with the eyes, the skin or clothing. Therefore wear
protective clothing, gloves and eye protection.
Do not tilt the battery, acid may emerge from the vent hole.
If acid is splashed into the eyes, rinse them immediately for several minutes with clear water. You must then
consult a doctor without delay.
If acid is splashed onto the skin or clothing, neutralise it immediately with a soap solutionand rinse with lots of
water.
Seek medical attention immediately if battery acid is accidentally swallowed.
Strictly no flames, sparks, naked light or smoking!
A highly explosive detonating gas is created when batteries are charged. The rooms where charging is carried
out must therefore always be well ventilated.
Avoid the formation of sparks when handling cables, wiring and electrical devices.
Turn the ignition lock to the 0 position before disconnecting or connecting the battery.
Do not place tools or any similar object on the battery (danger of short circuit and explosion hazard!).
61 20 ... Threshold values for battery assessment of all batteries (except
telephone batteries)
Safety instructions for handling vehicle battery.
Test step 1 - before battery charge
State of charge 1) Start output 2) Test result

cannot be tested Charge
less than 50 % 2) Charge
greater than 50 % less than 75% Charge
greater than 50 % greater than 75 % 3) Charge
greater than 80 % greater than 75 % OK
Test step 2 - after battery charge
State of charge 1) Start output 2) Test result

cannot be tested Faulty
less than 50% less than 75% Charge
greater than 50 % greater than 75 % Charge
1) State of charge and start output must always be evaluated in combination

2) Test charging for more than 5 hours with Gossen CG 32 or Siemens / Gossen VB 801 charger
3) Fully charge until the state of charge is greater than 80%.
Note:
If the battery has been tested from the positive terminal in the engine compartment, repeat the test for safety directly on
the battery.
61 20 503 Vehicle battery - closed-circuit current monitoring

To access the battery earth lead, perform the necessary preliminary
work described in the document Disconnecting battery earth lead.
Do not disconnect the battery earth lead!
Note:
If several 12 V batteries are installed in the vehicle:
Closed-circuit current check is possible on the vehicle battery only.

Connect the clip-on probe to the battery earth lead of the vehicle
battery. The arrow on the clip-on probe must point towards the vehicle
battery.
Measure closed-circuit current.
Important!
battery:

Turn off ignition.
Switch on ignition.

03 Body
Voltage supply
Activate rest state
Power-down command
61 21 028 Charging battery
Warning!
Read and comply with safety informations pertaining to vehicle
battery.
Attention!
Lead-acid battery, AGM battery:
To prevent the intelligent battery sensor from malfunctioning, use
the charging points in the engine compartment.
Observe instructions on intelligent battery sensor/battery electronics.
Note:
Use BMW-recommended charging computers* to charge the battery.
*Sourcing reference BMWÂ Workshop Equipment Catalogue
Pay attention when charging the lithium ion battery!
The charging voltage generated by existing chargers designed for

the lead-acid or AGM batteries is too high for the lithium-ion battery.
In the event of excessive charging voltage, the Li-ion battery
isolating switch can open, generating among things a ccm message
in the cluster.
Before charging a lithium ion battery, adjust the charging voltage of
existing charger adapters once.
Follow notes on lithium ion battery.
61 21 028 Recharge vehicle battery
1 – Charging battery
Observe the notes on handling the vehicle battery.
For additional information see:
61 00 ... Safety information on handling the vehicle battery
61 00 / 12 00 ... Notes on disconnecting and connecting the vehicle battery
61 12 ... Notes on the intelligent battery sensor (IBS)
▶ Charging lead-acid batteries and AGM batteries

Connect to a charger approved by BMW.
If the battery is charged while it is still installed: always connect the charger
to the jump start terminal point in the engine compartment.
Fully charge the battery.
The battery is fully loaded once the charge current drops below a certain
value:
Battery temperature Charge current
15° C - 25° C <2.5 A
< 15°C <1.5 A
Disconnect the charger after having completed charging.
▶ Charging the lithium ion battery
Comply with notes on handling lithium ion batteries.
For more information see:
08 08 14 (094) Charging parameters for lithium ion batteries
61 12 ... Notes regarding intelligent battery electronics (lithium ion battery)
Adapt the charging voltage on the charger to the lithium ion batteries.
Too high charging voltage can lead to opening of the electronic disconnect
switch.
Connect to a charger approved by BMW.
Fully charge the battery.
Disconnect the charger after having completed charging.
Links
General repair instructions Used in step
61 20 ... Notes on AGM battery 1
61 20 ... Notes regarding the lithium ion battery 1
61 12 ... Notes on intelligent battery sensor (IBS) 1
61 12 ... Notes regarding the battery electronics (lithium ion battery) 1
Special tool service information Used in step

Description of the manual Li parameter setting for DEUTRONIC DBL800/1200/1600 1
Description of the manual Li parameter setting for ELEKTRON HS-1000 1
Description of the manual Li parameter setting for ELTEK MultiCharger 750/900/1500 1
Special tool service information Used in step

Charging parameters for lithium ion batteries 1
Note for the workshop equipment catalogue BMW, MINI 1
1. Qualification:
controls.
2. Identification:
vehicle!
water foam).
engine is running.
any other work.
and damage.
be replaced.
safety screws.
61 25 ... Assessing the transport capability of cell block in service
workshops
Warning!
The following points must be strictly observed prior to starting work:
Safety information for handling electric / hybrid vehicles.

Visual check of the high-voltage battery unit following an accident
Initiating:
For analysis and disposal purposes, it is necessary to transport an already used cell module. These lithium-ion
based cell blocks are to be classified as hazardous material according to UN 38.3, and may only be
transported under particular prerequisites.
Obtaining the certified transportability between the assessment and delivery of the cell block to the disposal /
transportation company is the responsibility of a qualified person. For shipping one also needs to take into
account the influence of the storage requirements and other possible occurring events for the determined
transportability.
The transport in the sense of the hazardous goods legislation is organised in three areas:
1. Assessment of the transportability
2. Transport preparation
3. Performing the transport
This document contains all the necessary information in order to assess the transportability of a used cell
block. The transport preparation and execution is not an element of this document.
Further information on this can be found in the information bulletin in the ASAP.
It will be explained which measures are necessary in order to assess the transportability.
How these measures are to be performed individually depends on the particular situation at the location and
is not an element of this document. These procedures are to be defined according to the local regulations /
laws and recorded as valid local work instructions.
Prerequisites from a security perspective:

The analysis and assessment of the cell block is to be performed by an "expert for working on HV intrinsically
safe vehicles".
The certificate of the transportability is the responsibility of the qualified person.
The following specifications for work safety must also be observed:
Storage of cell blocks
For dual-cell modules, the module connector should be disconnected.
The information for this can be found in the information bulletin in the ASAP.
Note:
This document must be printed out and archived with the vehicle data.
Assessment cell block
NAME Date Serial no. VIN
Signature: ------------------------------------------------------------
The electrical assessment of the cell module takes place via the diagnosis and test module.
The de-energised state of the high-voltage battery unit is to be determined before it is removed from the
vehicle.
De-energise the high-voltage system.
Transport preventing faults according to the diagnosis or the test Yes No

module
Visual assessment:
Smoke Yes No
Evidence of fire damage Yes No
Heat development Yes No
Crack or opening on the housing Yes No
Dents on the housing, deformation, damage Yes No
Loose connections, loose or damaged Yes No
Serial number not readable Yes No
Suspected water damage Yes No
Cell module, transport capable No Yes
The serial number must be clearly legible. If the serial number can no longer be read, the housing of the cell
block must be clearly marked with the serial number.
The electrical and visual assessment must be set down in writing!
If one or more points is/are answered with yes the following procedure must be clarified with technical
support! Furthermore, the high-voltage battery unit that has been removed must be blocked off with high-
voltage barrier tape. If the high-voltage battery unit is still in the vehicle, the vehicle must be made
inaccessible and blocked off.
61 25 ... Notes on repair of high-voltage battery unit
1. Prerequisite
Various organisational prerequisites need to be fulfilled before the repair of a high-voltage battery unit is
permitted and can be carried out in an expedient way. These prerequisites concern both, the commercial
company and the service employee.
The repair of a high-voltage battery unit is intended to be carried out exclusively by commercial companies
featuring the service format BMW i Service Extended Battery or BMW i Service Full.
A commercial company featuring the service format BMW i Service Basic is able to remove and install a high-
voltage battery unit but cannot perform any repair work on or in the high-voltage battery unit. If a repair is
required according to the test schedule in the diagnosis system, the vehicle or the high-voltage battery unit
must be transported to a commercial company featuring the service format BMW i Service Extended Battery
or BMW i Service Full. The repair is to be carried out in such a workshop.
The commercial company must make available the required special tools and a suitable workbay for the repair.
The most important special tools are the following:
Mobile lift table MHT 1200 + set of adapters to remove and install the high-voltage battery unit
Charger for cell blocks of high-voltage battery unit
Diagnosis system for the repaired high-voltage battery unit
Lifting tackle to remove and install cell blocks
Panel wedges made of plastic to remove clips within the high-voltage battery unit
Lifting traverse for the complete high-voltage battery unit
High-voltage barrier tape
Yellow cones relating to high-voltage recommended
Sourcing reference:
See Aftersales Assistance Portal (ASAP) - Service/Technical - Workshop Equipment (Start BMW) - Shop
Workshop Equipment or at www.bmwgroup.com
Only service employees being qualified for the repair of the high-voltage battery unit may carry out this
procedure.
This includes training for "experts for work on high-voltage-intrinsically safe vehicles".
Before removing and opening the high-voltage battery unit, troubleshooting is to be carried out by means of
the relative diagnosis system. Only if determined by the test schedule and if the prerequisite „no mechanical
damage on the outside“ is satisfied, the high-voltage battery unit may be opened and the faulty component
identified by the test schedule can be replaced. No other repair work relating to the high-voltage battery unit
than the replacement of faulty components is planned.
It is essential to observe the operational steps specified in the repair instructions very precisely in order to
carry out the replacement of a faulty component. The use of the special tools listed therein is absolutely
essential as well.
2. Safety rules
The first step after opening the housing cover to repair the high-voltage battery unit is a visual inspection
for mechanical damage.
A thorough visual inspection of the components inside the working area is required during and/or before
and after every operation. When removing one component, all other involved components being
accessible need to be checked for damages. If the housing or other internal high-voltage components
are damaged, a qualified electrician or Technical Support must be contacted. All repair works relating to
the high-voltage battery unit must be stopped immediately for safety reasons
Check the correct latch mechanism of the connector of the insulation monitoring line at the control unit of
the high-voltage battery unit. If this is not fully locked, an isolation fault may not have been detected.
The separation of the high-voltage cable between the two cell modules mounted on the inside of the
housing (across from the connection side of the high-voltage battery unit) is to be always carried out
before working on the opened high-voltage battery unit. This procedure ensures the interrupt of the
series connection (additional safety)
The workbay required for the repair of the high-voltage battery unit must be clean (free of grease, dirt and
swarf), dry (no leaking fluid) and free of flying sparks. Therefore, avoid close vicinity to areas intended for
cleaning of vehicles and to workbays intended for repair work relating to the body. Use movable walls for
separation, if needed
High-voltage barrier tape is required to secure the workbay against unauthorised access (insufficient
qualification, customers, visitors, etc.). It is also required in case the high-voltage intrinsic safety is not
established or the status is not determined yet. Placing yellow cones with lightning bolt to indicate high-
voltage when leaving the working area is recommended
Do not use tools or other objects with pointed and sharp blades/edges when working on high-voltage
components or high-voltage cables and/or in their close vicinity. Diagonal cutting pliers, knives etc. are
prohibited. Cable straps inside the low-voltage wiring harness may be opened by means of diagonal
cutting pliers
Allowed: Plastic wedges
Cable straps relating to high-voltage cable may not be cut open. Damaged clips remain on the high-
voltage cable. The remaining, damaged clip must be pushed to a position on the high-voltage line where
the clip can not rub. A new clip must then be installed
Defective or damaged high-voltage cables must be made unusable to ensure they are not reused
No tools must be forgotten inside the high-voltage battery unit. Check whether all tools are present in the
tool box before closing the housing cover
It is absolutely essential to remove all small parts/screws that fell into the high-voltage battery unit. The
use of magnetized screws is generally recommended in order not to lose any screws in the high-voltage
battery unit during the repair
When interruptions of work occur: Secure housing cover against unintended opening by screwing in
several screws. Enclose the working area by means of high-voltage barrier tape
Due to the very slim construction of the radiator, the risk of damage during disassembly and installation is
high. Careful handling is absolutely necessary as the cooling of the cell blocks may not be guaranteed
when the radiator is damaged (bent, dented). The consequence is a major loss of the electrical range and
of the power of the vehicle. In extreme cases, even a breakdown may occur
Very careful handling is necessary when disconnecting and connecting the insulation detector line at the
control unit of the high-voltage battery unit (safety box coming) since high-voltage is present in the thin
orange lines. Do not pull on the lines (e.g. to unplug the connector etc.)! The connector must be locked
securely when plugged in
Make sure the plastic lids of the modules are not removed when working on the cell modules (loosing
screws, raising and lifting, …). The live cell contacting system is located thereunder. Continuing to work
with the lid being removed is not permitted. A qualified electrician or Technical Support must be contacted
A schematic diagram with limiting sample examples in the training is necessary to get to know the limits.
These show when the further work for the "experts for intrinsically safe vehicles" is no longer possible
due to absent intrinsic safety, and the Technical Support or a qualified electrician must be contacted
Remove residual moisture and coarse contamination around the lid of the high-voltage battery unit before
beginning the disassembly
Clean gaskets and sealing surfaces (venting unit, high-voltage connector, signal connector, radiator
connection) with a specified cleaning agent before reassembly
If contamination is present in the high-voltage battery unit, check the cause and carefully clean the
affected areas
Approved cleaning agent:
Spirit
Windscreen cleaner
Glass cleaner
Distilled water
Vacuum cleaner with plastic top
Visual inspection for contamination and damage of housing as well as of connections and degassing unit
when installed (underfloor). A damaged diaphragm within the venting unit may indicate damaged storage
cells. In this case, special carefulness is required when checking and opening the high-voltage battery
unit
Electrolyte
The majority of the electrolyte is a mixture of lithium-nickel-manganese-cobalt oxide in bound state The
quantity of free electrolyte in the high-voltage battery unit is very small. It is a noxious and irritant fluid.
Absolutely avoid direct contact of skin with leaking fluid as acid burns may occur. In case of contact with
eyes or skin, flush with plenty of clear water and consult a doctor immediately. Burning or evaporating
electrolyte is also hazardous. CAREFUL: do not inhale! Ensure sufficient fresh air supply. If breathing
ceases, apply artificial respiration and immediately consult a doctor. Notify fire brigade in case of fire. Clear
the area immediately and make accident scene safe. Attempt to extinguish the fire without putting
persons in danger and use suitable extinguishant, e.g. water
3. Repairing removed high-voltage battery units
The high-voltage battery unit is a component of large dimensions and heavy weight. Only the combination
of the housing and the cell blocks mounted therein provides the high-voltage battery unit with complete
stability (rigidity), as required for driving. Therefore, it is necessary to ensure that the housing is
positioned on the relative mounting/adapter of the lifting table during replacement and fixation of cell
blocks. In this way, one can prevent the housing from bracing during the repair work and ensure the high-
voltage battery unit is not installed in the BMW I01 in this condition
It is extremely important to enter the serial numbers and the installation positions of the replaced
components in the SME via the testing device, as well as to carry out the transmission into the diagnosis
system. Otherwise, the new installation position will be assigned automatically by the SME. The
consequence is an incorrect location data, as the SME does not set correct positions. For a renewed
repair of the high-voltage battery unit, the diagnosed faults for the incorrect installation position will be
displayed. The consequence is that replacement is done at the wrong location
In diagnosis, it is not possible to enter the serial numbers of the cell supervision circuits. The serial
numbers are transmitted from the cell supervision circuit to the SME using the CAN bus. The SME then
sets a corresponding position assignment. This assignment is not always fault-free. That is why the serial
number and installation position of the exchanged cell supervision circuit must be checked in the
diagnosis after completed repair. If the positions do not match, a position change can be performed with
diagnosis. A new serial number of a cell supervision circuit is not entered
Attention: Do not use powered wrenches as the screws/threads located in the high-voltage battery unit
may break due to the low torques!
The seal must be renewed every time the housing cover is removed to guarantee tightness of the high-
voltage battery unit
The screws are thread-tapping, so pre-insert them manually before tightening them with a tool. Otherwise,
the threads of the lower housing section may be damaged!
1. Qualification:
controls.
2. Identification:
vehicle!
water foam).
engine is running.
any other work.
and damage.
be replaced.
safety screws.
and hybrid vehicles
Attention!
connections:
connection.

the arrow.
Attention!

Note:

Attention!

Warning!
must be replaced!


housing.
Attention!

Attention!
the risk of danger.

Press lock (1).

the KLE:
Attention!
under the lock (2).
Attention!
connector housing.

Attention!
connector housing.

line):
of arrow (2).
Attention!
connector housing.
61 31 996 Carrying out steering angle sensor adjustment
Important!
In vehicles with active steering, steering angle sensor adjustment is
integrated in the service function ”Initial operation/adjustment for
active steering” and must not be carried out separately!
Note:
Steering angle sensor adjustment must be carried out:
Before adjustment work on the front axle/steering
after all mechanical work on the steering system
E36 Z3, E38: If Dynamic Stability Control (DSC) is installed
E46 (All-wheel drive vehicle), E53, E83: After the battery has been
disconnected
After the following components have been
replaced/encoded/programmed:
Fixture for switches of steering column / switch cluster /
steering angle sensor
Dynamic Stability Control (DSC) control unit
Control unit active anti-roll stabilization (ARS)
Connect the vehicle to the diagnosis system or Software Service

Station.
Select and carry out steering angle sensor adjustment under Service
functions.
61 35 680 Initialise rain sensor
Note:
Initialisation is necessary:
after replacing windscreen
after replacing the rain sensor
after installing a used rain sensor
Note:
Initialise rain sensor
61 31 033 Removing and installing light switch unit
Unclip left wooden finisher,

refer to 51 16 221.
Remove left glovebox,
refer to 51 16 350.
Release screws (1).
Press switch unit up a little through glovebox aperture and then slide
back.
Unlock plug and remove.

61 31 057 Removing and installing switch unit in center console
Version with SMG transmission only:

Remove trim for storage tray.
Version with automatic transmission only:
Remove finisher for preselector lever.
All:
Remove trim for center console.
Remove insert in function carrier.
In version with on-board monitor, remove heater controls.
Loosen screws (1).
Loosen screws (1).

Pull out function carrier for switch center (2) in direction of arrow.
Disconnect plug connections (1) and (2) and remove function carrier for
switch center (3).
61 31 299 Removing and installing/replacing clutch switch module

Note:
Clutch master cylinder (2) is removed for purposes of clarity.
Lever out clutch switch module (1) from clutch master cylinder (2) with
screwdriver.
Unlock plug (4) and disconnect from housing (3).
Installation:
Clutch switch module is secured against incorrect installation.
Clutch switch module must snap audibly into place.
61 31 005 Removing and installing/replacing fixture for steering column
stalk
Warning!
Move wheels into straight-ahead position and do not alter this
position during the repair work.
With steering wheel removed, do not under any circumstances
turn/twist fixture for steering column stalk!

Remove steering wheel
Remove lower section of steering column trim
Remove top section of steering column casing.
Disconnect plug from ring antenna.
Disconnect plug from wiper switch.
Disconnect plug from turn indicator/dipping switch.

Release screws (1) and remove fixture for steering column stalk.
Warning!
When removed, the cover (1) of the fixture for the steering column
stalk (2) is secured against turning/twisting by the lock (3).
Do not under any circumstances twist the cover (1) out of its
centered position against the fixture for the steering column
stalk (2).
61 31 036 Removing and installing/replacing operating unit for light switch
unit
Unclip left trim,

refer to 51 16 221.
Remove left glovebox,
refer to 51 16 350.
Remove light switch unit,
refer to 61 31 033.
Unclip operating unit.

61 35 175 Removing and installing/replacing rain sensor
Up to 09/2001:

Remove interior rear-view mirror
Pull out retaining clips (2) in each case in direction of arrow and remove.
Unclip rain sensor (3) at bottom in direction of arrow.
Disconnect plug connection (1) and remove rain sensor (3).
Installation:
Do not damage optical element below rain sensor (3).
If necessary, initialize rain sensor.
From 09/2001:
Version with rain/light sensor.
Expand two-part mirror base cover (1) by pressing from below and
detach.
Feed out two-part mirror base cover (1) and remove.

Press locks (1) in direction of arrow and remove rain/light sensor (2)
towards bottom.
Installation:
Do not damage optical element below rain/light sensor (2).
If necessary, initialize rain/light sensor.
61 31 104 Removing and installing/replacing shifters for SMG transmission
(both)

Remove airbag unit

Release screws (1).
Remove both shifters for SMG transmission (4) forwards from sports
steering wheel (3).
Installation:
Make sure electrical leads are correctly routed.
Make sure both turning locks (1) of each shifter for SMG transmission (2)
are correctly seated in the respective mounts.
61 31 208 Removing and installing/replacing switch for front lumbar support
This operation is described in:

”Removing outer cover on front seat”.
61 31 055 Removing and installing/replacing switch for SMG transmission
(program selector switch)

64 1 020
M3:
Unclip trim for storage tray (1) sideways and lift.

Unclip switch for SMG transmission (2) in direction of arrow from trim for
storage tray (3) and remove.
All:
Unclip trim for storage tray (1) with special tool 64 1 020 and raise in
direction of arrow.
Unclip switch for SMG transmission (2) in direction of arrow from trim for
storage tray (3) and remove.
61 31 040 Removing and installing/replacing switch for windscreen wipers

Remove fixture for steering column stalks
Press locks (1) and windshield wiper stalk (2) in direction of arrow out of
fixture for steering column stalk (3).
61 31 016 Removing and installing/replacing turn indicator/headlight
dipping switch

Remove fixture for steering column stalks
E85, E86 only: Remove cruise control switch
Press locks (1) and feed direction indicator/dipping stalk (2) in direction of
arrow out of fixture for steering column stalk (3).
61 31 313 Replacing a brake lining sensor

Remove wheel
Open plug housing (1).

Unclip lead of brake lining sensor (2) from plug housing (1).
Disconnect associated plug connection of lead from brake lining
sensor (2).
Feed lead from brake lining sensor (2) out of fixtures.
Press clip (1) together and detach brake lining sensor (2) in direction of
arrow from brake caliper (3).Installation:
Make sure clip (1) and brake lining sensor (2) are correctly seated in
brake caliper (3).
61 31 310 Replacing brake-light switch

Note:
Brake light switch (2) is situated above the brake pedal.

Pull brake light switch (2) in direction of arrow out of brake light switch
holder (3).
Press catches (4) together and unclip brake light switch holder (3) from
brake pedal.
Installation:
Depress brake pedal.
Slide brake light switch (2) as far as it will go into brake light switch
holder (3).
Grip brake light switch holder (3), slowly return brake pedal to starting
position and pull back to stop.
61 31 295 Replacing clutch switch for cruise control system

Press clutch pedal with pedal support down to flow and lock in
position.

Withdraw sleeve (3) in direction of arrow up to stop.
Press both retaining clips together at front end and pull out switch (2) in
direction of arrow towards rear.
Installation:
Slowly move clutch pedal to initial position.
61 31 492 Replacing level switch for windshield washer system

Release fluid reservoir for windshield washer system and place
to one side
Note:
Drain fluid reservoir for windshield washer system (3).

Turn level switch for windshield washer system (2) in direction of arrow
and remove towards bottom from water reservoir for windshield washer
system (3).
61 31 348 Replacing microswitch for unlocking rear lid
Remove strip handle (on rear lid).
Remove clip (1) in direction of arrow.

Installation:
Make sure clip (1) is correctly seated.
Remove switch for unlocking rear lid (2) in direction of arrow from
fixtures (3).
Cut wires on switch for unlocking rear lid (2) to length and strip insulation.
Crimp stop parts.
61 31 115 Replacing rocker switch for side-window operation
Version with SMG transmission only:

Remove trim for storage tray.
All:
Unclip gaiter (1) sideways and force upwards over shift knob (2).
Loosen screws (1).

Raise base of storage tray (2).
Unlock retaining clips and unclip rocker switch for window operation.
Disconnect plug.
61 31 204 Replacing switch combination for seat adjustment

”Removing outer cover on front seat”.
All models except Convertible:

Carry out programming/coding.
61 31 255 Replacing switch for door mirror
Detach control knob (1) upwards from switch for door mirror (2).
Important!
When detaching switch for door mirror (2):
Pull upwards only, do not press sideways.
Using a pair of pointed pliers, pull door mirror switch (2) upwards slightly at
rod (1) and lift out completely by hand.
Disconnect plug connections (1) and remove switch for door mirror (2).
61 31 079 Replacing switch for hazard warning system/central locking

Version with sequential M transmission only:
Remove storage compartment trim
Version without sequential M transmission only:

Unclip gaiter (1) at side and force upwards over gear lever knob (2).
All:
Release screws (1).
Fold storage compartment floor (2) up at rear and place to one side.
Raise storage compartment (1) at front slightly.

Press side catches and press switch for hazard warning system/central
locking from below out of storage compartment (1).
Disconnect plug connection and remove switch for hazard warning
system/central locking.
61 31 224 Replacing switch on impact cushion for left or right airbag
Remove airbag unit from steering wheel.
Illustration shows removal of switch on impact cushion for airbag on

left
Loosen screws (2).
Remove switch on impact cushion for airbag (3) in direction of arrow.
61 31 228 Replacing switch on sport steering wheel (with connected airbag
unit)

Remove airbag unit
Note:
There 2 screw variants:
Self-tapping screws
Screws with insert nuts (secure against falling out)

Unclip complete trim (4) in direction of arrow from fixtures (3).
Disconnect plug connection underneath.
Release screws (1).

Detach switch on sport steering wheel (3) in direction of arrow from
trim (2).
Installation:
Ensure gap dimension is uniform between trim (2) and switch on sport
steering wheel (3).
61 31 058 Replacing switch unit in center console
Remove and install switch unit in center console
Loosen screws (1).

Remove switch unit (2) from function carrier for switch center (3) in
direction of arrow.
61 00 ... Encode/program control unit(s)
Note:
Depending on the vehicle and the equipment, the following flat rate unit
items are available for programming/encoding:
61 00 710
61 00 720
61 00 730
Note:
In order to avoid incorrect programming procedures and fault
messages, it is essential when working with the ISTA/P
programming system always to use the version.
Battery voltage must not drop below 13.0 V during programming.
Only use chargers* recommended by BMW for low voltage vehicle
electrical system.
*Sourcing reference Workshop Equipment Catalogue
programming routine via ISTA/P:

Accept action plan with the control units to be programmed/encoded
and enabled, if necessary or work through.
Observe the reworking list!
If applicable, connect the workshop system to the vehicle
depending on the rework list, run the brief test and delete the fault
memory.
Note:
A switch to the workshop system may not necessarily be required
with the integration of the service functions and the "Delete fault
memory" function in ISTA/P. Check the rework list accordingly!
61 35 680 Initialise rain sensor
Note:
Initialisation is necessary:
after replacing windscreen
after replacing the rain sensor
after installing a used rain sensor
Note:
Initialise rain sensor
Replacement:
Programming
Coding
61 35 ... Notes on ESD protection (Electro Static Discharge)

12 7 060
Note:
Electrical components which are particularly sensitive to electrostatic
discharge (electronic control units, sensors, etc.) are marked with the
ESD warning symbol.
E‐Electro
S‐Static
D‐Discharge
Important!
Read and comply without fail with the notes on this subject from
Service Information 2 06 04 128.
Statically charged persons can discharge themselves when they touch

electrical components.Note:
Humans can only detect a discharge starting from a level of approx.
3000 V.
The danger threshold for electrical components already starts from a
level of approx. 100 V.
Example:
Mechatronic control unit.
Important!
Do not touch pins and multi-pin connectors directly!
Touch electrical components by their housings only.
Important!
To avoid damaging or destroying electrical components as a result
of electrostatic discharge, it is absolutely essential to observe the
following instructions:
When replacing electrical components, leave the replacement
components in their original packaging until immediately before
they are to be installed
If necessary, always return a removed component in its
original packaging (always pack the component away
immediately)
Read and comply with user information on using the
associated special tool 12 7 060
Personal protective equipment:

Electrically conducting clothing (high wool content, antistatic shoes
required).
These can primarily be identified by the logo on the side.
61 35 ... Overview, rain sensor (additional work when replacing the
windscreen / sensor replacement)
1-Series: E8x
3-Series: E9x
5-Series: E6x
6-Series: E6x
X1: E84
Z4: E89
Sensor type/ With windscreen When replacing When Connecting the

replacement replacing diagnosis system
Sensor shape the sensor/
replacement sensor the sensor/ required
Programming/encoding
required Initialisation
necessary required
Condensation Yes No No No
sensor
square
30 x 20 mm
5-Series: E6x
6-Series: E6x
7-Series: E6x
Sensor type/ With windscreen When replacing When replacing When Connecting
replacement replacing the
Sensor shape the sensor substitute visuals diagnosis
replacement the system
sensor Programming/encoding Programming/encoding sensor/
required
visuals
Initialisation
required
all types No Yes - Yes Yes
square
60 x 40 mm
RLS No - No Yes Yes
approximately (new substitute
ø 50 mm visuals required,
refer to Electronic
Parts Catalogue)
X5: E70
X6: E7x
Sensor type/ With When replacing When replacing When Connecting
windscreen replacing the
Sensor shape replacement the sensor substitute visuals diagnosis
the system
replacement Programming/encoding Programming/encoding sensor/
sensor required
visuals
Initialisation
required
RLPSS (Rain, Yes Yes - Yes Yes

light and
precipitation solar
sensor)
(Designation is
located on the
back of the
sensor)
approximately ø
50 mm
RLS (vehicle with No - No Yes Yes
no HUD)
(new
(Designation is substitute
located on the visuals
back of the required,
sensor)
refer to
approximately ø Electronic
50 mm Parts
Catalogue)
RLSS (vehicle Yes Yes - Yes Yes
with HUD)
(Designation is
located on the
back of the
sensor)
approximately ø
50 mm
1-Series: E8x
3-Series: E9x
X1: E84
X3: E83
Z4: E89
Sensor
shape replacement sensor Programming/encoding Initialisation required
required required
necessary
square
60 x 40 mm
5-Series: F1x
5 Series GT: F07
6-Series: F06, F1x
7-Series: F0x
X3: F25
X4: F26
Sensor type/ With windscreen When replacing the When replacing When Connecting
replacement sensor replacing the
Sensor substitute visuals diagnosis
shape replacement Programming/encoding the system
sensor required Programming/encoding sensor/
necessary required
necessary substitute
visuals
Initialisation
required
all types No No - Yes Yes
approximately
ø 35 mm
all types Yes Yes - Yes Yes
approximately
ø 50 mm
Only for F25 : No - No Yes Yes
RLS (new substitute
visuals required,
approximately
ø 50 mm refer to Electronic
Parts Catalogue)
X5: F15, F85

X6: F16, F86
Sensor shape
required required
necessary
approximately ø
35 mm
1-Series: F2x
2-Series: F2x
3-Series: F3x, F8x
3 Series GT: F34
4-Series: F3x, F8x
Sensor type/ With windscreen When replacing the When Connecting the
replacement sensor replacing the diagnosis
Sensor shape sensor system
replacement Programming/encoding
sensor required Initialisation required
necessary required
all up to 03/2014 except SBS No No Yes Yes
(01)
back of the sensor)
SBS (01) No No No No
back of the sensor)
All as from 03/2014 No No No No
2-Series: F4x
necessary
BMW i:
Sensor shape
required required
necessary
approximately ø
35 mm
BMW from G series
necessary
MINI (all):
Sensor shape
required required
necessary
square
60 x 40 mm
approximately ø
35 mm
Rolls-Royce:
RR1
RR2
RR3
RR4
RR5
RR6
Sensor shape
required required
necessary
square
60 x 40 mm
all types No No Yes Yes
approximately ø
35 mm
all types Yes Yes Yes Yes
approximately ø
50 mm
Rolls-Royce:
RR11
RR12
Sensor shape
required required
necessary
approximately ø
35 mm
61 35 910 Removing and installing (replacing) the control unit of the
electronic immobiliser
Attention!
discharge (ESD protection)!

Disconnect battery negative cable
Remove trim panel for pedal mechanism

Note:
Secure the control unit of the electronic immobiliser (3) from falling down.
Release screws (2) and remove the control unit of the electronic
immobiliser (3).
Replacement: Attention!
Check the hardware version of the old control unit.
Part numbers of the control units with hardware version HW03:
61 35 8 374 957
61 35 6 905 666
61 35 6 905 667
61 35 6 905 670
61 35 8 387 447
If hardware version HW03 was installed, the following must be
observed:
Unpin cable from pin three of the connector, (observe the notes
regarding opening and unpinning).
Replace the double flat spring contact by a larger one.
Insert cable in pin two of the connector.
Carry out programming/encoding.
61 35 122 Removing and installing/replacing general module
Important!
Read out programming/coding.

Print out and make a note of settings for car and key memory
in CKM menu

Disconnect negative battery cable
Remove right glovebox with housing
Release plastic nut (1).

Unclip device holder (2) from fixtures (3).
Unlock plug connections (4) and disconnect.
Press catch (6) and remove general module (5) towards rear.
Replacement:
Check printed-out or noted-down settings for car and key memory
in CKM menu and reset if necessary
61 35 175 Removing and installing/replacing rain sensor
Up to 09/2001:

Remove interior rear-view mirror
Pull out retaining clips (2) in each case in direction of arrow and remove.
Unclip rain sensor (3) at bottom in direction of arrow.
Disconnect plug connection (1) and remove rain sensor (3).
Installation:
Do not damage optical element below rain sensor (3).
If necessary, initialize rain sensor.
From 09/2001:
Version with rain/light sensor.
Expand two-part mirror base cover (1) by pressing from below and
detach.
Feed out two-part mirror base cover (1) and remove.

Press locks (1) in direction of arrow and remove rain/light sensor (2)
towards bottom.
Installation:
Do not damage optical element below rain/light sensor (2).
If necessary, initialize rain/light sensor.
61 35 900 Removing and installing/replacing ring antenna of electronic
immobilizer

61 3 300

E46 only: Remove lower section of steering column trim
Slide in special tool 61 3 300 with flattened end (A) facing ring antenna
and lever out ring antenna.
61 13 ... Main relay connector for DME
Open locking clamp (1) for the corresponding cable.

retaining hooks (2) of appropriate contact and pull out cable with contact.
61 13 ... Relay carrier
Place special tool 61 1 153 against relay carrier (1) and carefully pull in
direction of arrow until the locking tabs (2) of the relay carrier are raised
up.
Pull relay carrier (2) in direction of arrow into the first catch (3).
Press down arrester hook (4) of corresponding contact and pull out the
cable with contact.
With special tool 61 1 136 or 61 1 137 (press out) press out dual spring
contacts.
61 61 ... Adjusting left or right windscreen wiper

61 6 100
Correctly adjusting the contact angle of the wiper arms on the windscreen increases wiping
quality. For adjustment, refer to the vehicle-specific repair instruction.
A/B = Distance between windscreen wiper blade (2) and trim panel on cowl panel (1)
Note: Measurement is taken at the height of the locators (3) for the windscreen wiper arms
C= Contact angle between wiper blade centre plane and windscreen
When adjusting with special tool 61 6 100 , set the scale value in accordance with the following table.
For RHD vehicles, change the preceding sign of the scale values.
LHD cars, scale range 0 to ‐-10
RHD cars, scale range 0 to +10
Model Contact angle (C) on windscreen Scale value (LHD) on Adjustment dimension (A, B) on windscreen
wiper arm special tool wiper arm
Front passenger side Driver side Front passenger Driver Front passenger Driver Rear end
side side side side
1’ E81 85.5 ° 85.5 ° -5 -5 47±3 mm 54±3 mm
+1.5° ‐-1.0° +1.5° ‐-1.0°
E82 85.5 ° 85.5 ° -5 -5 47±3 mm 54±3 mm
+1.5° ‐-1.0° +1.5° ‐-1.0°
E87 85.5 ° 85.5 ° -5 -5 47±3 mm 54±3 mm
+1.5° ‐-1.0° +1.5° ‐-1.0°
E88 85.5 ° 85.5 ° -5 -5 47±3 mm 54±3 mm
+1.5° ‐-1.0° +1.5° ‐-1.0°
3’ E46 85.7° ±1° 85.3° ±1° -4 -5
E90 86.7° ±1° 86.0° ±1° -3 -4 88±3 mm 95 ±3 mm
E91 86.7° ±1° 86.0° ±1° -3 -4 88±3 mm 95 ±3 mm 35±3 mm
E92 86.7° ±1° 86.0° ±1° -3 -4 75 ±3 mm 84 ±3 mm
E93 86.7° ±1° 86.0° ±1° -3 -4 75 ±3 mm 84 ±3 mm
5’ E39 86.5° ±1° 86.5° ±1° -4 -4 60.1±1 mm
E60 86.0° ±1° 86.0° ±1° -4 -4 69 ±3 mm 87±3 mm
E61 86.0° ±1° 86.0° ±1° -4 -4 69 ±3 mm 87±3 mm 30 ±3 mm
6’ E63 86.0° ±1° 86.0° ±1° -4 -4 69 ±3 mm 87±3 mm
E64 86.0° ±1° 86.0° ±1° -4 -4 69 ±3 mm 87±3 mm
7’ E38 87.0° ±1° 87.0° ±1° -3 -3 65 ±3 mm 58 ±3 mm
E65 85.5° ±1° 87.0° ±1° - - 20±3 mm 48±3 mm
E66 85.5° ±1° 87.0° ±1° - - 20±3 mm 48±3 mm
E67 85.5° ±1° 87.0° ±1° - - 20±3 mm 48±3 mm
8’ E52 85.5° ±1° 85.5° ±1° -4 -4 38 ±2 mm 104
±2 mm
X E53 85.0° ±1° 85.0° ±1° -5 -5 54±3 mm 55 ±3 mm 32.5
±2 mm
E70 85.6° ±1° 85.0° ±1° -4 -5 103±3 mm 90±3 mm 39 ±2 mm
E71 85.6° ±1° 85.0° ±1° -4 -5 103±3 mm 90±3 mm
E83 85.2° ±1° 85.4° ±1° -5 -5 66 ±3 mm 61 ±3 mm 29 ±1 mm
Z E85/E89 85.5° ±1° 85.5° ±1° -4 -4 57±2 mm 52 ±2 mm
E86 85.5° ±1° 85.5° ±1° -4 -4 57±2 mm 52 ±2 mm
61 61 010 Checking/adjusting approach angle of windshield wiper arms on
front windscreen
Note:
Wiping quality is increased if the approach angle of the windshield
wiper arms is precisely adjusted.
Place special tool 00 9 331 next to center of rotation of windshield wiper

blade on windshield.
Note:
To prevent scratching of wiper arm, cover wiper arm with fabric
adhesive tape.
If the approach angle is too large (light gap at top between gauge and
wiper blade), grip wiper arm special tool 00 9 332 and turn with special tool
00 9 333 in direction of arrow.
Note:
To prevent scratching of wiper arm, cover wiper arm with fabric
adhesive tape.
If the approach angle is too small (light gap at bottom between gauge
and wiper blade), grip wiper arm special tool 00 9 332 and turn with special
tool 00 9 333 in direction of arrow.
61 61 010 Checking/adjusting contact angle of windscreen wiper arms on
windscreen

00 9 220
00 9 331
61 6 100
Note:
Wipe quality is improved by precise adjustment of contact/approach
angle of wiper arms.
Adjustment angle can be checked with special tool 00 9 331 or
61 6 100 .
Checking with setting gauge:

Before checking approach angle, briefly lift windscreen wiper arms off
windscreen.
Place special tool 00 9 331 next to pivot point of wiper blade on
windscreen.
Check light gap, adjust wiper arm if necessary.
Note:
Tape off wiper arm with fabric adhesive tape to avoid damage.
Press special tools 00 9 220 in appropriate direction until correct

contact/approach angle is obtained.
Checking with angulometer:
Remove wiper blades.
Insert windscreen wiper arm (1) in angulometer 61 6 100 .
Using screw (2) and pressure plate (3), locate windscreen wiper arm (1)
and position on windscreen.
Read off value in degrees, adjust wiper arm if necessary.
Note:
Windscreen wiper arm (1) must rest correctly on lower and side
contact surfaces (4) of angulometer 61 6 100 .
On right-hand-drive cars, screw (2) must be located on left side of
Press special tools 00 9 220 in appropriate direction until correct

contact/approach angle is obtained.
61 61 270 Removing and installing complete wiper console
Remove cowl panel cover.


Unscrew bolt (2).
Installation:
Installation:
Fit rubber grommet (1) of wiper console on pin (2).
Release nuts and feed out complete wiper console through opening in
heater bulkhead.Installation:
61 61 100 Removing and installing/replacing both windshield wiper arms

61 6 060
Take off cap.
Unfasten nut.Installation:
Observe tightening torque 61 61 10AZ.
Important!
Do not bend windshield wiper arm during removal (risk of breakage).
Detach windshield wiper arm with special tool 61 6 060 .

Installation:
Check that sleeve (1) is firmly seated.
If sleeve (1) is loose, it must be replaced.
A sleeve (1) firmly seated in the windshield wiper arm can be reused.
Windshield wiper arm with firmly seated sleeve (1):

Return windshield wiper system to rest position. Push wiper arm (2) with
firmly seated sleeve (1) onto shaft and tighten down.
Check setting of wiper arm (2).
To correct setting, replace sleeve (1).
Windshield wiper arm with new sleeve (2):

Return windshield wiper system to rest position.
Push wiper arm (1) with sleeve (2) onto shaft and tighten until hand-tight.
Set position of relevant wiper arm to rest position and then tighten down
wiper arm.
Adjustment dimensions:
Measurement 1 [mm] Measurement 2 [mm]

24 44
61 61 041 Replacing both windshield wiper blades
Press retaining spring in direction of arrow. Pull windshield wiper blade

towards wiper arm and feed out.
61 67 040 Adjusting spray nozzles for headlight cleaning system

00 9 100
64 1 020
Low-beam headlamp:
The spray contact point must be located in the center of the low-beam
headlamp.
To adjust, slowly pull out spray nozzle fully with aid of special
tool 64 1 020 and adjust spray contact point with special tool 00 9 100 .
High-beam headlamp:
The spray contact point must be located in the center of the high-beam
headlamp.
To adjust, slowly pull out spray nozzle fully with aid of special
tool 64 1 020 and adjust spray contact point with special tool 00 9 100 .
Note:
After checking the contact points, turn ignition off and on again before
repeating the spray procedure. The function of the headlight cleaning
system is otherwise disabled for approx. 3 minutes. Refer to function
description in Diagnosis and Information System.
61 67 045 Removing and installing/replacing spray nozzles for left or right
headlight cleaning system
Note: Drain fluid tank for windshield washer system
Lever out spray nozzle with telescopic nozzle and pull out up to stop.
Hold telescopic nozzle and pull off spray nozzle.
Allow telescopic nozzle to slowly slide back again.
Installation:
Make sure spray nozzle engages correctly on telescopic nozzle.
Installation:
Do not confuse spray nozzles.
Pay attention to R and L markings on underside of spray nozzles.
Replacement only:
Converting spray nozzle finisher:
Unclip both retaining hooks at bottom.
Remove spray nozzle finisher upwards from spray nozzle.Installation:

Adjust spray nozzles of headlight cleaning system.
61 67 010 Removing and installing/replacing washer pump of headlight
cleaning system
Note: Drain fluid tank for windshield washer system

Remove clip for hose (2) in direction of arrow.
Detach hose (3) from washer pump of headlight cleaning system (4).
Turn washer pump of headlight cleaning system (4) in direction of arrow
and lift out of water reservoir for windshield washer system (5).
Installation:
Replace sealing ring/strainer of washer pump.
Coat sealing ring of washer pump with antiseize agent.
Ensure hose is laid without kinks.
Fill fluid tank for windshield washer system.
61 71 004 Adjusting windshield washer spray nozzles
Note:
The sprays must strike in the center of the area.
Measurements apply to LHD models.
Measurements are mirror-inverted for RHD models.
Reference edge: windshield seal.
A1 265 mm C1 500 mm
A2 445 mm C2 350 mm
B1 400 mm D1 260 mm
B2 270 mm D2 550 mm
Mark points of contact with adhesive tape.

Adjust spray nozzles using special tool 00 9 200.
61 71 100 Removing and installing/replacing windshield washer pump
Note:
Drain fluid tank for windshield washer system
Unclip heat shield and place to one side.

Detach hose (2) from windshield washer pump (3).
Turn windshield washer pump (3) in direction of arrow, lift out of water
reservoir for windshield washer system (4).
Installation:
Replace sealing ring/strainer of washer pump.
Coat sealing ring of washer pump with antiseize agent.
Ensure hose is laid without kinks.
61 71 061 Replacing fluid tank for windshield washer system
Note:
Drain fluid tank for windshield washer system
N42 only:
Remove intake hood.

Release screw (2).
Unclip heat shield (1) in direction of arrow from lug (2) and place to one
side.Installation:
Make sure heat shield (1) is correctly engaged.
Version without headlight cleaning system:
Turn washer pump (1) in direction of arrow, lift out of water reservoir for
windshield washer system (2) and place to one side.
Lift out water reservoir for windshield washer system (2).
Version with headlight cleaning system:

Turn windshield washer pump (1) and washer pump of headlight cleaning
system (2) in each case in direction of arrow, lift out of water reservoir for
windshield washer system (3) and place to one side.
Lift out water reservoir for windshield washer system (3).
All:
Turn level switch for windshield washer system (1) in direction of arrow,
remove downwards from water reservoir for windshield washer
system (2) and place to one side.
Remove cover and strainer from water reservoir for windshield washer
system.
Installation:
Feed lugs (1) of water reservoir for windshield washer system (2) in
direction of arrow into lugs (3).
Installation:
Replace sealing rings/strainers on washer pumps.
Coat sealing rings of washer pump with anti-friction agent.
Make sure hoses are laid without kinks.
62 21 000 Removing and installing complete instrument carrier
Move steering column completely down and extend fully.
Note:
Steering wheel remains installed. Shown without steering wheel for
purposes of clarity.
Unfasten screws and fold instrument carrier forwards.

62 21 001 Replacing instrument carrier
Remove complete instrument carrier,

refer to 62 21 000.
Unlock clips (1) and detach trim (2).Installation:

Code instrument carrier,
refer to DIS.
63 10 ... Adjust the fog lights (with electronic headlight adjustment device
MAHA Lite 3)
Comply with test prerequisites for headlight adjustment!
Refer to the operating instructions for the headlight adjustment

device!
Switch on the headlight adjustment device by pressing any button.

Press F2 button. The shown display screen appears.
Perform the following settings:
1. The passenger car must be selected.
2. Enter the setting dimension for the headlight with buttons F1/F2:
- 2,0 %
3. The right / left-hand traffic must be selected according to the
country.
4. Select the fog light type with the F3 button:
EC: for halogen fog lights
EC LED: for LED fog lights
The adjusted values are adopted for future measurements.
Press briefly the button for the applicable side of the vehicle (1)
until symbol (2) appears.
The following symbols appear in the display:
O. K. (4): Adjustment is optimal.
O. K. (3): Adjustment is within the legal tolerance range. Adjust fog
light until O. K. (4) is displayed.
Arrows (5): Adjustment is incorrect. Adjust fog light using arrows (5)
until O. K. (4) is displayed.
63 10 ... Adjust the high-beam headlight (with electronic headlight
adjustment device MAHA Lite 3)
Important!
The high-beam headlight can only be adjusted in the following
cases:
The low-beam headlight and high-beam headlight are located in
separate housings and each has a separate range of
adjustment (e.g. E52, BMW i 01).
Low-beam headlight and high-beam headlight are located in
one housing with one separate range of adjustment each.
With separately mounted additional headlights (e.g. MINI).
On vehicles from 1995, separate adjustment of the high-beam
headlight is not possible.
(Exception E52, BMW i 01, additional headlight MINI)
Comply with test prerequisites for headlight adjustment.

device!

Adjust the low-beam headlight

1. The passenger car must be selected.
2. Enter the setting dimension of the headlight via the buttons F1/F2: -
1.0 % to - 1.1 %
(see "light/dark boundary of the headlight in the headlight
adjustment device" in the document observe the test
prerequisites for the headlight adjustment).
country.
4. Select the headlight type via the button F3:
EC: for halogen and xenon headlights
EC LED: for LED headlight

O. K. (4): Adjustment is within the legal tolerance range. Adjust high-
beam headlight until O. K. (5) is displayed.
Arrows (3): Adjustment is incorrect. Adjust high-beam headlight
using arrows (3) until O. K. (5) is displayed.
63 10 ... Adjust the low-beam headlight (with electronic headlight
adjustment device MAHA Lite 3)
Comply with test prerequisites for headlight adjustment!

device!
Note:
On vehicles with anti-glare high-beam headlight it is sufficient to
adjust the low-beam headlight.
Only in the event of a customer complaint regarding
dazzle/glare Adjust anti-glare high-beam headlight separately.

1. Passenger car must be selected
2. Enter the setting dimension of the headlight via the buttons F1/F2:
- 1,0 % to - 1,1 %
(see "light/dark boundary of the headlight in the headlight
adjustment device" in the document observe the test
prerequisites for the headlight adjustment).
country.
4. Select the headlight type via the button F3:
EC: for halogen and xenon headlights
EC LED: for LED headlight
Important!
Before measuring/adjusting the low-beam headlight, it is
absolutely necessary to determine the transparent screen of the
headlight!
An incorrect selection leads to an incorrect setting!
Transparent screen Type I:

Transparent screen Type II:

Press longer the button for the applicable side of the vehicle (3)

O. K. (5): Adjustment is within the legal tolerance range. Adjust
headlight until O. K. (2) is displayed.
Arrows (6): Adjustment is incorrect. Adjust headlight using arrows (6)
until O. K. (2) is displayed.
63 10 014 Adjusting fog lamps
Observe test preconditions for adjusting headlights.
Saloon/sedan, touring up to 09/2001:

Adjust fog lamp (1) at adjusting screw (2).
Saloon/sedan, touring from 09/2001:

Note:
Tools required:
Offset hexagon head screwdriver (size 4 mm) with ball head (1).
Using above-mentioned tool through opening (2), turn adjusting screw of

fog lamp (3).
Coupé, convertible:
Saloon/Sedan, Touring, Coupé, Convertible with M/aerodynamics

package:
If necessary, unclip trim.
compact:
Compact with M/aerodynamics package:

63 10 Adjusting headlight for RHD/LHD vehicles
When crossing borders into countries where they drive on the other
side of the road from that where the car was registered, it is
essential to cover the asymmetrical wedge in the low beam
headlight. The following illustrations show the covered areas in
question.
Note:
Any adhesive residue may only be removed with the supplied
cleaning cloth.
Fig. 1 shows the headlights on a left-hand-drive car.

Fig. 2 shows the headlights on a right-hand-drive car.
Note:
On cars fitted with xenon lights, it is not necessary to tape off the lights as they have their own adjustment facility; refer to
the Owner's Manual.
63 10 004 Adjusting headlights
Comply with test prerequisites for headlight adjustment,

refer to 63 10 Test prerequisite
Carry out headlight adjustment at adjusting screws (1) and (2).

A definite allocation of adjusting screws is not possible. Various
adjustments are always made in both directions.
1. Adjustment screw primarily for vertical adjustment
2. Adjusting screw primarily for lateral adjustment
3. Adjust the height at the adjusting screw (1)
US version only:
Only carry out the setting of the lateral adjustment when the plug in
the adjusting screw for the lateral adjustment is missing or is
damaged
If necessary, remove damaged plug with suitable tool
4. Make the lateral adjustment at the adjusting screw (2)
US version only:
If the lateral adjustment is checked or corrected, press the new
plug into the adjusting screw for the lateral adjustment without any
damage
63 10 ... Light patterns from different low-beam headlight types
The following equipment-specific and model-specific headlight types are

used in BMW Group vehicles:
Halogen headlights (low-beam and high-beam headlights)
Xenon headlights (low-beam and high-beam headlights)
LED headlights (low-beam and high-beam headlights)
Laser headlights (high-beam headlight booster, low-beam and high-
beam headlights are lit by LEDs)
Every headlight type has its specific transparent screen for the low-beam
headlight. In spite of these differences, all headlight types meet statutory
specifications.
The images below show transparent screens from the left headlight in
the low-beam headlight switch position projected onto a wall (no
automatic setting!).
The transparent screens from the right headlight are the same.
The transparent screens correspond with those in an accumulator box of
a headlight adjusting device.
Important!
For headlight adjustment with electronic headlight adjusting devices,
it is essential to determine the light pattern type!
Type I: Light pattern shows a continuous increase in the light/dark boundary.

Type II: Light pattern screen shows a short increase in the light/dark boundary.
1. Halogen headlight
Type I
2. Halogen headlight US version R60 only
3. Xenon headlights
Type II
4. LED headlight e.g. F01, F02, F03

Type II
5. LED headlight e.g. F06, F12, F13, E71
Type I
63 10 ... Notes on headlight adjustment (overview of adjustment
options of the lighting functions)
The following light-related components are used in BMW Group vehicles on an equipment-specific and model-
specific basis:
Headlight types:
Halogen headlights (low-beam and high-beam headlights)
Xenon headlights (low-beam and high-beam headlights)
LED headlights (low-beam and high-beam headlights)
Laser headlights (high-beam booster)
Headlight:
Headlight (low beam and high beam; cornering light, daytime driving lights, adaptive headlight, laser high-
beam booster, dynamic marker light)
High-beam headlight*
Fog light (fog light, cornering light)
Headlight dynamic marker light (dynamic marker light, no fog light)
Light functions:
Lighting function Setting possible Setting tool

Low-beam headlights Yes - Non-electronic headlight adjusting
device
- Electronic headlight adjusting device
High-beam headlight No,
Adjusted with the low-beam
headlight *
Automatic high beam No,
(main-beam assistant) Adjusted with the low-beam
headlight *
Non-dazzle high beam Yes, - Non-electronic headlight adjusting
headlight device
headlight - Electronic headlight adjusting device
Yes (with test module) Adjustment aid for headlight
Additional laser headlight No,
headlight
Adaptive Headlight No,
headlight
Fog lights Yes - Non-electronic headlight adjusting
device
Dynamic marker light Yes (with the test module) - Non-electronic headlight adjusting
device
(to F-series)
Adjustment aid for headlight
Dynamic marker light No,
(from G-series) Adjusted with the low-beam
headlight
Cornering light No
Daytime driving lights No
*A setting is only possible for models with a separate housing for the high beam (E52, I01, MINI additional
headlight).
Important!
All lighting functions specified above can be adjusted both with a non-electronic as well as with an
electronic headlight adjusting device.
63 10 ... Test requirements for headlights vertical aim adjustment
Attention!
Do not perform headlight adjustment immediately after
lowering the vehicle on the vehicle hoist. In this case,
move the vehicle for approx. 15 m on its own wheels
before headlight adjustment.
Attention!
Observe the operating instructions for the headlight
adjusting device!
The headlight adjusting bay must comply with the
specifications as set out in StVZO (German road traffic
licensing regulations) § 29 Annex 8d (or ISO 10604)!
These specifications are described in “Planning
principles for layout of BMW service workshops”.
(Can be found in the ASAP portal, Chapter 3.2.6.1 Headlight
adjusting bay)
Park vehicle on flat and even surface.

Replace faulty glass and mirrors and blackened light bulbs.
Check correct adjustment of headlights in relation to engine
compartment lid (gap dimensions).
Check tyre pressure and correct if necessary.
Only halogen headlight, fog light and headlight for dynamic marker
light (dynamic spotlight):
Apply load equivalent to one person on driver's seat (approx.
75 kg).
Vehicle with full fuel tank or appropriate additional weight in luggage
compartment.

Manual headlight beam throw adjustment: Move handwheel to
neutral position (1).
Light switch must be in "low beam/driving light" position (3).
Do not carry out the headlight adjustment in the "automatic driving
lights control" light switch position (2).
Version with Xenon or LED (automatic headlight beam throw
adjustment): Wait 80 s after switching on lights. During this time, do
not move the vehicle and avoid vibrations.
Attention!
Do not move the vehicle and steering wheel during the
measuring and adjustment procedures!
Wheels must be in the straight-ahead position!
Attention!
A correct measurement/adjustment requires exact positioning of the headlight adjusting device (1)!
The headlight adjusting device (1) must stand vertically to the vehicle longitudinal axis!
This applies to all headlights!
Position the headlight adjusting device (1) centrally in front of the vehicle (2) at distance (A) = 10 cm.
Align the headlight adjusting device (1) by laser beam (3). Laser beam (3) must hit two suitable points, e.g. marked by
arrows.
Attention!
Points must be vehicle proof!
Points must be separated as wide as possible!
Trim panels are not suitable!
If the headlight adjusting device (1) does not have a laser beam (3), complete the alignment analogous with the line in the
mirror.
Attention!
Always perform positioning of the headlight adjusting
device (1) at the outer headlight (2)!
The centre of the collecting lens (1) must match the centre of
headlight (2) horizontally.
Corrections are made by raising or lowering the headlight adjusting
device.
When positioned correctly, the light/dark boundary of the headlight (marked with arrow) must hit the collecting lens of the
adjusting device in the centre:
1. The headlight adjusting device is too low.
2. The headlight adjusting device is positioned correctly.
3. The headlight adjusting device is too high.
The centre of the collecting lens (1) must match the centre of
headlight (2) vertically.
Corrections are made by sliding the side of the headlight adjusting
device to the left or right.
Note:
The figure shows an example for the transparent screen of halogen headlights.
Overview of transparent screens of different headlight types.
Set the marker line {M} on the headlight adjusting device to dimension {e}. Scale graduations on the headlight adjusting
device are equal to a gradient in cm at a distance of 10 metres.
Light/dark boundary of headlights in headlight adjusting device
{e} Setting dimension, headlights:

Value is indicated on the headlight housing and on vehicles with production date up to 2011 on the type plate in
%.
(e.g.: 1.0 % = -10 cm/10 m = - 1.0 % on the headlight adjusting device)
Value 1.0 % (adjustment value - 1.0 %) applies to all BMW Group vehicles.
Exception: E53, E70, E71, E72, E83, F15, F16, F25, F26, R60, R61, F60. For these vehicles, value 1.1%
(adjustment value - 1.1%) applies.
Setting dimension, fog lights:
Value 2.0% = -20 cm/10 m = - 2.0% on the headlight adjustment device applies to all BMW Group vehicles.
{H} Height of headlight centre above parking surface

{h} {H} - {e} = height of marking line above parking surface
+ Central mark = centre point of high beam headlight.
{M} Marker line of the headlight adjusting device
{S} Standing surface of the vehicle and headlight adjusting device
Adjustment dimension {e} is only valid for EUR. Observe differing national regulations.
holders!
Note:

63 12 ... Headlight fogging fault pattern
Note:
Certain weather conditions can lead to fogging on the inside of the
headlight lens.
This is not necessarily a fault that requires replacement of the headlight.
Top row (A): Permissible fogging. Headlight does not need to be replaced.
Bottom rowÂ (B): Impermissible fogging. Replace the headlight.
63 99 ... Notes for replacing the protective cap of the headlight
Important!
Risk of damage!
Damaged seals on the protective caps will lead to moisture
penetration into the headlight.
This will in turn cause porous cable insulations and malfunctioning of
the headlight.
When working on the headlight system, check the protective cap seals.
Replace the protective cap in the event of damage!
Example: screwed protective cap

Seal (1) on protective cap (2).
Example: latchable protective cap

63 12 001 Removing and installing/replacing left headlight
Coupé/Convertible from 03/2003:

Remove left headlight (xenon headlight).
All others: Necessary preliminary tasks:

Remove direction indicator lamp.
Remove trim from headlight housing.
Note:
Illustration shows air cleaner cover removed for purposes of clarity.
Unlock and disconnect all plug connections on headlight.
Release screws (1) and (2) and lever out headlight towards
front.Installation:
Tighten screws (1) hand-tight only.
Pull headlight fully towards front.
Close hood and adjust headlight to fit.
Open hood and tighten down screws (1).
Install and tighten down screws (2).
Installation:
Adjust headlights.
63 12 005 Removing and installing/replacing left headlight (xenon headlight)
CoupÃ©/Convertible from 03/2003:

All others:
Remove spray nozzles of headlight cleaning system.
Remove left headlight.
67 16 010 Removing and installing/replacing left headlight vertical aim
adjuster (halogen headlight)

64 1 020
Warning!
Follow instructions for handling light bulbs (exterior lights).
Caution!
Do not touch headlight reflectors with your bare hands.
Remove lens/reflector for left headlight.

All models except US:
Remove sidelamp bulb holder from headlight.
Disconnect plug connections for low and high beams.

Turn retaining rings and remove both bulb holders.
Remove cover frame towards front from headlight.

Note:
For purposes of clarity, illustration shows removed headlight.
Detach covers for low and high beams.Installation:

Make sure covers are correctly seated.
Saloon/sedan, touring from 09/2001 only:

All:
Press headlight insert at an angle towards front/bottom until inner
headlight vertical aim adjuster snaps audibly out of its guide.
Turn thumbwheel (1) clockwise until internal adjusting element is free
(headlight insert can then be tilted out towards front!).
Installation:
Make sure adjusting element is correctly seated in guide.
Turn thumbwheel (1) approx. 10 turns counterclockwise.
Make sure headlight insert at bottom is correctly seated on ball socket of
internal headlight vertical aim adjuster.

Tilt headlight insert (2) in direction of arrow out of headlight housing (1)
and feed out of ball socket (3).
Installation:
Make sure headlight insert (2) is correctly seated on ball socket (3) of
headlight housing (1).
All others:
Feed headlight insert (1) out of guide and remove towards

front.Installation:
Make sure headlight insert (1) is correctly seated in guide.
Note:
Installation:
Insert guide (1) on headlight insert into rail (2).
Unclip inner plug (1) with special tool 64 1 020 in direction of arrow.
Pull out plug (1) in direction of arrow.

Release screws (2) and remove headlight vertical aim adjuster (3) in
direction of arrow.
Installation:
Make sure cable (4) is correctly seated in guides (5).
All others:
Note:
Disconnect plug.
Release screws and remove headlight vertical aim adjuster.
All:
Installation:
Adjust headlights.
adjuster (xenon headlight)
Warning!
Caution!

Remove lamp for xenon light.
Remove halogen bulb for high-beam headlight.
Remove cover frame (1) in direction of arrow from headlight housing (2).
Turn sidelamp bulb holder (2) in direction of arrow and remove.

Remove high beam cover (1) in direction of arrow.
Installation:
Make sure high beam cover is correctly seated.
All models except M3:
To install cover for high beam, if necessary release control unit holder for
xenon headlight.
All:
Press headlight insert (1) at an angle towards front/bottom until inner

headlight vertical aim adjuster (2) snaps audibly out of its guide (3).
Turn thumbwheel (1) clockwise until headlight insert (2) is free.

Tilt out headlight insert (2) in direction of arrow and feed out of guide (3).
Remove headlight insert (2).
Installation:
Make sure headlight insert is correctly seated in guide (3).
Then clip headlight insert (2) onto ball socket of inner headlight vertical
aim adjuster.
Installation:
Insert guide (1) on headlight insert into rail (2) of headlight housing.
If necessary, make sure pin (3) of adjusting lever for right/left-hand traffic
is correctly seated in bore (4).
Disconnect plug.
Installation:
Adjust headlights.
63 12 034 Removing and installing/replacing lens cover for left headlight
(halogen headlight)
Remove turn signal lamp.

Remove trim from headlight housing.
Unclip cover strip from outside to inside.
Unclip all retainers.

Remove lens cover.
Installation:
If necessary, replace headlight seal.
Contact point of headlight seal is situated on radiator side (high beam
headlight) in area of clip.
63 12 037 Removing and installing/replacing lens cover for left headlight
(xenon headlight)
Remove and install/replace lens cover for headlight.
63 12 035 Removing and installing/replacing lens cover for right headlight
(halogen headlight)
Remove and install/replace lens cover for headlight (halogen headlight).
63 12 038 Removing and installing/replacing lens cover for right headlight
(xenon headlight)
Remove and install/replace lens cover for headlight.
63 12 002 Removing and installing/replacing right headlight
Remove and install/replace headlight.
63 12 006 Removing and installing/replacing right headlight (xenon
headlight)
Remove headlight (xenon headlight).
67 16 015 Removing and installing/replacing right headlight vertical aim
Remove and install/replace headlight vertical aim adjuster.
Remove right headlight (xenon headlight).
holders!
Note:

63 12 950 Replacing a lower holder for headlight mounting
Remove headlight.
Release screws and remove lower holder.

Installation:
Tighten screws hand-tight only.
Install headlight and align to engine hood.
Version with headlight cleaning system:

Unclip clip for hose (1) and disconnect hose (2).
63 99 132 Replacing bulb for side lights, front left
Warning!
US only:
Replacing bulb for front turn indicator.
All except US:
M54 only:
Release intake silencer housing and set aside.
Turn bulb holder for side light in direction of arrow and pull out towards
rear.
Pull out bulb from bulb holder for side light.Installation note:
Note bulb type.
63 99 133 Replacing bulb for side lights, front right

Replacing bulb for side light, front left
63 12 860 Replacing control unit for left xenon headlight (saloon/sedan,
touring)
Warning!
Version with xenon headlights: Danger to life due to high voltage!
Therefore disconnect all components from voltage supply before
removal.
Work on the entire xenon lighting system (ignition unit, control unit
and lamp) may only be carried out by specialist personnel.
Up to 09/2001:
Loosen screws (1).
Pull xenon headlight control unit holder with control unit for xenon
headlight (2) in direction of arrow out of guides and place to one side.
Installation:
Ensure correct cable routing.
Loosen screws (1).

Detach control unit for xenon headlight (3) from holder of control unit for
xenon headlight (2) and remove.
From 09/2001:
Loosen screws (1).
Remove control unit for xenon headlight (2).
63 12 861 Replacing control unit for right xenon headlight
Replace control unit for xenon headlamps.
63 12 870 Replacing ignition unit for left xenon headlight (saloon/sedan,
touring)
Warning!
Version with xenon headlights: Danger to life due to high voltage!
Therefore disconnect all components from voltage supply before
removal.
Work on the entire xenon lighting system (ignition unit, control unit
and lamp) may only be carried out by specialist personnel.

Remove left headlight insert (xenon headlight).
Up to 09/2001:
Loosen screws (2).
Remove ignition unit for xenon headlight (3).
From 09/2001:
Loosen screws (1).
Raise ignition unit for xenon headlight (2) and disconnect plug
connection (3).
Remove ignition unit for xenon headlight (2).
63 12 871 Replacing right ignition unit for right xenon headlight

Replacing ignition unit for left xenon headlight
63 13 150 Removing and installing/replacing complete front left or right turn
signal lamp
Up to 09/2001:
Open hood.
Press down retainer (1) through bore in side panel and slide turn signal
lamp towards front.
Installation:
Make sure bonded rubber seal (1) is correctly seated on trim (2).
From 09/2001:
Open hood.
Loosen screw (1).
Installation:
Observe tightening torque, 63 13 2AZ.
Note:
Secure front turn signal lamp (2) against falling out.
Slide out front turn signal lamp (2) in direct of arrow.

Installation:
Make sure nut (1) is correctly seated on headlight housing (2).
If necessary, when screwing front turn signal lamp into place, secure
nut (1) with screwdriver (3) against turning.
Installation:
When sliding in front turn signal lamp (1), make sure guides (2) are
correctly seated in headlight mounts (3).
Make sure bonded seal is correctly seated under front turn signal
lamp (1).
All:

Note:
Turn signal lamp, front left:
To release, turn bulb holder (2) clockwise.
Turn signal lamp, front right:
To release, turn bulb holder (2) counterclockwise.
Turn bulb holder (2) and remove turn signal lamp (3).
Installation:
Make sure seal is correctly seated between bulb holder (2) and turn
signal lamp (3).
63 13 200 Removing and installing/replacing front left or right additional
turn signal lamp (saloon/sedan, touring)

64 1 020
Up to 09/2001:
Lever out additional front turn signal lamp (1) with special tool 64 1 020 in
direction of arrow.
Pull out additional front turn signal lamp (1) up to bulb holder, turn through
approx. 90° and feed out.
From 09/2001:
Unclip additional front turn signal lamp (1) in direction of arrow and
remove.
All:
Disconnect plug connection (1) and remove additional front turn signal
lamp (2).
63 99 273 Replacing bulb for turn indicator, front left
Warning!

Turn bulb holder for turn indicator bulb (1) in direction of arrow and pull out
of headlight (2) towards rear.
Pull bulb for turn indicator (1) out of turn indicator bulb holder (2).

Remove complete front turn-signal lamp.
Remove bulb.
All: Installation:
Note type of bulb.
63 99 275 Replacing bulb for turn indicator, front right
CoupÃ©/Convertible from 03/2003: Necessary preliminary tasks:

Detach washer fluid reservoir for windshield washer system and
place to one side.
All:
Replace bulb for front turn-signal lamp.
63 17 000 Removing and installing/replacing left or right fog lamp insert
(saloon/sedan, touring)

00 9 317
Up to 09/2001:
Lever out fog lamp insert (1) with special tool 00 9 317 and fold out in
direction of arrow.
Installation:
Feed detent lugs (1) into outer guide (2).
Clip inner fog lamp insert into retainer.
Disconnect plug connection and remove fog lamp insert.Replacement:

Adjust front fog lamps.
From 09/2001:
Left side only: Remove outside temperature sensor.
Remove cover from front wheel housing.
Release screws (2) and remove fog lamp insert (3) in direction of arrow.
Installation:
Make sure ventilation grommet is laid without kinks and is sufficiently
firmly seated.
Replacement:
Adjust front fog lamps.
63 17 030 Removing and installing/replacing left or right foglamp insert
(M/aerodynamics package)

64 1 020
Version 1:
Place special tool 64 1 020 in opening (2) and unclip trim (1) in direction of
arrow.Installation:
Make sure trim (1) engages correctly.
Release screw (1).

Feed foglamp insert (3) in direction of arrow out of outer guides (2) and
remove.
Disconnect plug connection behind it and remove foglamp insert (3).
Installation:
Make sure foglamp insert (3) is correctly seated in outer guides (2).
Make sure ventilation grommet of foglamp insert (3) is laid without kinks
and is sufficiently firmly seated.
If necessary, adjust fog lamp.
Version 2:
Unclip trim (1) in direction of arrow. Installation:

Make sure trim (1) engages correctly.
Release screw (1).
Withdraw fog lamp insert (2) in direction of arrow.
Disconnect plug connection behind it and remove foglamp insert (2).
Installation:
Feed lugs (3) into outer guides (4).
Make sure ventilation grommet of foglamp insert (2) is laid without kinks
and is sufficiently firmly seated.
If necessary, adjust fog lamp.
63 21 180 Removing and installing/replacing left or right rear light (in side
panel)
Remove socket housing for rear light.
Saloon/Sedan, Coupé and Convertible:

Detach luggage compartment wheel arch liner in rear area.
Release nuts and remove rear light towards outside.
Coupé and convertible only:
Replacement:
Convert side trim on rear light (inside).
touring:
Unscrew nut (1).
Release nuts (2) slightly and remove rear light (3) towards outside.
All:
Installation:
Make sure rear light seal is correctly seated, replace if necessary.
Make sure there is a uniform gap all round between outer rear light and
side panel.
63 21 183 Removing and installing/replacing left or right tail light (on rear
lid)
Release nut slightly.

Press lock in direction of rear light housing and remove rear light towards
outside.
Installation:
Make sure rear light seal is correctly seated, replace if necessary.
Make sure there is a uniform gap all round between outer rear light and
rear lid.
Installation:
Attach outer detent lugsÂ (1) to rear lid.
63 21 055 Replacing a socket housing for left or right rear light
(saloon/sedan, touring)
Saloon/sedan, in side panel:
Up to 09/2001:
Unlock catch (1) and remove socket housing for rear light (2).
From 09/2001:
Turn fastener (1) in direction of arrow and remove socket housing for rear
light (2).
Both:
Disconnect plug connection and remove socket housing for rear light.
Touring, in side panel:

Remove flap in luggage compartment trim panel.
Note:
Remove warning triangle before removing left socket housing for rear
light.
Unlock socket housing for rear light (1) and lift off slightly.
Disconnect plug connection (2) and remove socket housing for rear
light (1).
Saloon/sedan, touring, in rear lid:
Saloon/sedan:
Partially release panel for rear lid.
touring:
Release insert in rear lid trim.
Both:
Disconnect plug.
Unlock socket housing for rear light and remove.
63 31 000 Removing and installing/replacing complete ceiling light
Note: Secure complete ceiling light against falling out.
Version with inside reading lamps:

Lever out complete ceiling light (1) in direction of arrow.
Disconnect plug connection underneath and remove complete ceiling
light (1).
Version without inside reading lamps:

Lever out complete ceiling light (1) in direction of arrow.
Disconnect plug connection underneath and remove complete ceiling
light (1).
63 31 020 Removing and installing/replacing footwell light
Lever out footwell light (1) in direction of arrow.

Disconnect plug connection and remove footwell light.
63 31 150 Removing and installing/replacing glovebox light
Lever out glovebox light (1) in direction of arrow.

Disconnect plug connection and remove glovebox light (1).
63 31 015 Removing and installing/replacing left or right interior light (C-
pillar or hard top)
Note: Secure interior light against falling out.
Version with inside reading lamp:

Lever out interior light (1) in direction of arrow.
Disconnect plug connection underneath and remove interior light (1).
Version without inside reading lamp:

Lever out interior light (1) in direction of arrow.
Disconnect plug connection underneath and remove interior light (1).
63 31 050 Removing and installing/replacing mirror light
Important!
Follow instructions for handling light bulbs (interior lights).
Replacement:
If necessary, convert bulb.
Lever front mirror light (1) in direction of arrow.

Disconnect plug connection underneath and remove mirror plate light (1).
Replacement:
Note type of bulb.
63 99 ... Notes for handling bulbs / bulb light sources (exterior lights)
Warning!
Xenon headlight: Danger to life due to high voltage!
Disconnect all components from voltage supply before removal.
Work on the entire xenon lighting system (ignition device, control
unit and xenon bulb) may only be carried out by qualified personnel.
Warning!
Halogen bulbs are under pressure:
To avoid injury, wear protective goggles and gloves.
Warning!
LEDs are potentially dangerous due to their dazzling effect:
Do not look directly and unprotected into the light radiating from the
LED.
Important!
To avoid short circuits:
Disconnect bulbs / light sources from the voltage supply before
changing them (lighting system and ignition off).
Do not touch glass bulbs with bare hands, as even the smallest amount
of contamination will burn in and reduce bulb service life.
Only touch light bulbs with clean gloves or a clean cloth.
Do not expose light bulbs to mechanical vibrations.
Use only recommended light bulbs.
Follow the light bulb manufacturer's notes without fail.
63 99 ... Notes for replacing light bulbs (interior lights)
Important!
To avoid short circuits, disconnect bulbs from the power supply
before replacing them (lighting system and ignition off).
Do not touch the glass bulbs in new lights bulbs as even the slightest
contamination will burn in and reduce bulb service life.
63 99 ... Notes for replacing the protective cap of the headlight
Important!
Risk of damage!
Damaged seals on the protective caps will lead to moisture
penetration into the headlight.
This will in turn cause porous cable insulations and malfunctioning of
the headlight.
When working on the headlight system, check the protective cap seals.
Replace the protective cap in the event of damage!
Example: screwed protective cap

Example: latchable protective cap

63 99 295 Replacing bulb for auxiliary turn indicator light, front left or right
Warning!
Remove additional front turn signal lamp.
Turn bulb holder (1) and remove from additional front turn signal lamp (2).
Note:
Additional turn signal lamp, front left:
To open, turn bulb holder (1) counterclockwise.
Additional turn signal lamp, front right:
Saloon/sedan, touring from 09/2001: To open, turn bulb holder (1)
clockwise.
All others: To open, turn bulb holder (1) counterclockwise.
Pull bulb out of holder (1).

Installation:
Note type of bulb.
63 99 435 Replacing bulb for left or right interior light (C-pillar or hard top)
Caution!
Version with inside reading lamp:

Remove interior light.
Turn socket housing counterclockwise and remove.

Remove bulb.
Note:
1. Socket housing for inside reading lamp
2. Socket housing for interior light
Version without inside reading lamp:
Unclip lens (1).
Pull bulb (1) in direction of arrow from bulb holder.
All:
Installation:
Note type of bulb.
63 99 401 Replacing bulb for left or right number/license plate light
Warning!
Follow instructions for handling light bulbs (exterior lights) .
Lever out lens (1) on left or right from opening (2) and remove.
Lever out bulb (3).
Note:
Note bulb type .
63 99 132 Replacing bulb for side lights, front left
Warning!
US only:
Replacing bulb for front turn indicator.
All except US:
M54 only:
Release intake silencer housing and set aside.
Turn bulb holder for side light in direction of arrow and pull out towards
rear.
Pull out bulb from bulb holder for side light.Installation note:
Note bulb type.
63 99 133 Replacing bulb for side lights, front right

Replacing bulb for side light, front left
63 99 273 Replacing bulb for turn indicator, front left
Warning!

Turn bulb holder for turn indicator bulb (1) in direction of arrow and pull out
of headlight (2) towards rear.
Pull bulb for turn indicator (1) out of turn indicator bulb holder (2).

Remove complete front turn-signal lamp.
Remove bulb.
All: Installation:
Note type of bulb.
63 99 275 Replacing bulb for turn indicator, front right
CoupÃ©/Convertible from 03/2003: Necessary preliminary tasks:

Detach washer fluid reservoir for windshield washer system and
place to one side.
All:
Replace bulb for front turn-signal lamp.
63 99 315 Replacing bulb(s) for left or right rear light (saloon/sedan, touring)
Warning!

Saloon/sedan, in side panel:
Up to 09/2001:
Twist defective light bulb and pull out to remove.
Note:
1. Turn indicator
2. Tail/brake light
3. Tail light
From 09/2001:
Note:
1. Brake light
2. Turn indicator
3. Tail light
4. Tail light
Touring, in side panel:

Note:
1. Turn indicator
2. Tail light
3. Tail/brake light
In rear lid:
Saloon/sedan up to 09/2001, touring:
1. Reversing light
2. Left side: if necessary rear fog light
Right side: Not used
Saloon/sedan from 09/2001:
1. Reversing light
2. Left side: Tail light, if necessary rear fog lamp
Right side: Tail light
All:
Installation:
Note type of bulb.
63 99 445 Replacing bulb(s) for mirror light
Important!

Remove mirror light
Spread bow contacts (1) and remove bulb (2).
Installation:
Note type of bulb.
63 99 003 Replacing halogen bulb for high beam headlight on right

Replacing halogen bulb for high beam headlight on left
63 99 002 Replacing halogen bulb for high-beam headlight on left
Warning!

M54, N42 only:
Detach intake muffler housing and place to one side.

S54 only:
Remove intake hood and intake manifold.

N40 only:
Detach intake muffler housing and place to one side.
Note:
Turn protective cap (1) in direction of arrow and remove from
headlight (2).

Disconnect locking clip (2) in direction of arrow and fold upwards.
Remove bulb (3) from headlight (4).
Installation:
Make locking clip (2) is correctly engaged.
All others:
Unfasten plug connection and disconnect.
Turn retaining ring in direction of arrow and remove bulb holder towards
rear.
Note:
If retaining ring is tightly seated, press bulb holder forwards.
Remove bulb from bulb holder.

Installation:
Make sure bulb holder is correctly seated on headlight by correctly
engaging retaining ring
All models: Installation:

Note bulb type
63 99 230 Replacing halogen bulb for left or right fog lamp (M aerodynamics
package)
Warning!
Remove fog lamp.
Turn bulb with socket (1) and remove from fog lamp (2).Installation:
Note type of bulb.
63 99 201 Replacing halogen bulb for left or right front fog lamp
Warning!
Saloon/Touring from 09/2001:

Release screws (1).
Remove clip (2).
Feed out cover (3) from front bumper trim (4) and unclip in direction of
arrow.
Installation:
Make sure cover (3) is correctly seated on front brake air duct (5).

Turn bulb with bulb holder (2) in direction of arrow and remove.
Others:
Remove foglamp insert.
Turn bulb with bulb holder and remove.

All: Installation:
Make sure bulb holder is correctly seated and engaged in headlight
Note bulb type
63 99 437 Replacing light bulb for footwell light
Caution!
Remove footwell light.
Move lens coverÂ (1) in direction of arrow and remove.

Remove bulb (2) underneath.
Installation:
Note type of bulb.
63 99 451 Replacing light bulb for luggage compartment lighting
Caution!
Lever out lens in direction of arrow.
Remove bulb.Installation:
Note type of bulb.
63 99 431 Replacing light bulb(s) for ceiling light
Caution!
Version with inside reading lamps:

Remove complete ceiling light (with inside reading lamps).
Turn socket housing for bulb counterclockwise and remove.

Remove bulb.
Note:
1. Socket housing for left inside reading lamp
2. Socket housing for ceiling light
3. Socket housing for right inside reading lamp
Version without inside reading lamps:

Remove complete ceiling light (without inside reading lamps).
Loosen screws (1).

Remove ceiling light (2) from lens underneath.
Remove bulb(s).
All:
Installation:
Note type of bulb.
63 99 077 Replacing right lamp for xenon light
S54 only:
Detach filler neck and place to one side.
N42 only:
Remove intake hood.
Detach water reservoir for windshield washer system and place to one
side.
All:
Replace bulb for xenon light.
63 99 076 Replacing the bulb for the left xenon headlight (Saloon, Touring)
Warning!
Up to 09/2001:
Pull off low-beam headlight cover (1) in direction of arrow.
Installation note:
Make sure the cover of the low-beam headlight (1) and the tab (2) is
correctly fitted.
From 09/2001:
Unlock and remove the low-beam headlight cover (1).
If applicable, open and unscrew the cable clip (2).
Note:
Feed the low-beam headlight cover (1) out carefully to prevent damaging
components below it.
All:
Twist and remove the xenon light ignition unit (1) in the direction of the
arrow.
Twist the retaining ring (2) in direction of arrow and remove.
Remove the xenon light bulb.
Installation note:
Note bulb type.
Recommendation:
63 99 071 Replacing the halogen bulb for the left or right headlight
Warning!

Turn retaining ring in direction of arrow and remove bulb holder towards
rear.
Note:
Press bulb holder forwards if retaining ring is stiff.
Remove halogen bulb from bulb holder.

Installation note:
Note bulb type.
Installation note:
Insert bulb holder (2) into headlight (3). Make sure retaining lugs (1) are
correctly fitted in fixture (4) of the headlight (3).
Important!
Ensure correct engagement of the retaining ring.
Recommendation:
63 99 ... Safety information for handling bulbs / light sources (exterior lights)
Warning!
All headlight types, regardless of the type of light sources used,
can be dangerous due to their dazzling effect!
Do not look directly and for long periods of time into the light.
Warning!
Laser, LED and Xenon headlights in particular can be very
dangerous due to their dazzling effect:
Do not look directly and unprotected into the light.
Warning!
Xenon headlight: Danger to life due to high voltage!
Disconnect all components from voltage supply before removal.
Work on the entire xenon lighting system (ignition device, control
unit and xenon bulb) may only be carried out by qualified personnel.
Warning!
Halogen bulbs are under pressure:
To avoid injury, wear protective goggles and gloves.
Important!
To avoid short circuits:
Disconnect bulbs / light sources from the voltage supply before
changing them (lighting system and ignition off).
Do not touch glass bulbs with bare hands, as even the smallest amount
of contamination will burn in and reduce bulb service life.
equipment)
Warning!
Important!
direct sunlight.
Important!
Important!
fumes directly.
agent/paint.
cream.
Important!
First Aid:
Recycling:
64 00 ... Overview of A/C service station
The following table shows an overview of the currently offered A/C service station depending on the
refrigerant.Note:
The different refrigerant connections for C2H2F4 and R1234yf play no role during flushing, as the A/C
service station is connected with the refrigerant circuit of the vehicle via the refrigerant line from the air
conditioning compressor.
Description Order number Refrigerant Flushing Refrigerant Accessories for

of circuit flushing
R134a R1234yf Yes No Order number
Beissbarth 4100a 81 34 2 286 739 x x 81 34 2 286 908
760R 81 34 2 289 569 x x 81 34 2 289 571
WAECO AirCon Service 81 34 2 147 235 x x 81 34 2 286 909
Center
WAECO 2500 Low Emission 81 34 2 286 807 x x 81 34 2 286 909
TEXA 770S 81 34 2 286 318 x x
BEISSBARTH 5100yf 81 34 2 286 325 x x
WAECO BMW 5000 Low 81 34 2 286 324 x x
Emission
64 00 ... Overview of refrigerant oil to be filled
The following table shows an overview of which refrigerant oil may be added to which vehicle.Note:
The refrigerant oil to be filled can be found on the type plate on current vehicles.
Depending on the version and country, it may happen that the following table specifies a different
refrigerant oil than the factory-filled refrigerant oil. This is permissible in certain cases. Observe notes
on the refrigerant and refrigerant oil.
Model series R134a R1234yf ND-8 Sanden SP-A2

E All vehicles with combustion engines x x
E72 Hybrid x x
F All vehicles with combustion engines x x
(BMW and MINI) All vehicles with combustion engines x x
Hybrid x x
Hybrid x x
PHEV x x
PHEV x x
G All vehicles with combustion engines x x
All vehicles with combustion engines x x
PHEV x x
PHEV x x
I All x x
All x x
R All vehicles with combustion engines x x
(MINI) All vehicles with combustion engines x x
RR RR1, RR2, RR3 before model facelift x x
RR4 with optional rear air conditioning x x
All other vehicles x x
All other vehicles x x
64 11 260 Removing and installing / replacing auxiliary water pump
Remove water valve for heater with auxiliary water pump.
64 11 205 Removing and installing / replacing heater (automatic air
conditioner)
Draw off, evacuate and fill A/C system.

S54 only:
Warning!
Danger of scalding!
Release hose clamps (1) and (2).

Detach water hoses.
Carefully blow through lines to remove remaining coolant from heating
element.
Installation:
Filling and bleeding the cooling system,
Release screw.
Unfasten screws.
Remove pressure and intake pipes.
Installation:
If necessary, release unlocking mechanism and remove circulating air
flap.
Release nut (1) and lay double pipe (2) to one side.Installation:
Release screws (2) on bulkhead (1).

Remove complete storage tray.
Release shear screw (1) (e.g. mill off or rebore screw head). Unscrew
bolt (2).
Release screws and lower steering column.
Release screw.
Detach door seal (1) and trim (2) on A-pillar on left and right in direction of
arrow.
Unfasten transverse reinforcement on right and left.

Release head airbag on transverse reinforcement on right and left.
Disconnect heater plug connections.
Unfasten transverse reinforcement on right and left sides of center

console.
If necessary, cut open cable ties (1).

Turn lock (2) on left and right on fuse box through approx. 90° and fold
down fuse box.
Disconnect pivot (1) of fuse box on left and right at transverse
reinforcement towards top.
Remove transverse reinforcement.
Remove heater - A/C unit.
Installation:
Make sure condensate drain is correctly seated.
64 11 748 Removing and installing heater controls (A/C control)

64 1 010

Remove ignition key from ignition switch.
Pull fuse 63 from distribution box in glovebox.
Pull out heater controls (1) with special tool 64 1 010 .

Installation:
Note color coding of plugs.
64 11 749 Removing and installing heater controls (automatic air
conditioning)

64 1 010

Remove ignition key from ignition switch.
Pull fuse 63 from distribution box in glovebox.
Pull out heater controls (1) with special tool 64 1 010 .

Installation:
Note color coding of plugs.
64 11 750 Removing and installing heating control (heater)
Remove radio.
Press down rotary buttons.
Release screws and remove front panel towards rear.
Loosen screws (1).

Remove center fresh air grill.
Unlock retainers (2) and push control panel inwards.
Remove frame (3).
Unlock retaining clips and withdraw shaft.

Unlock retaining clips and unclip Bowden cable.
Feed out Bowden cable.

Unlock retaining clips and pull out microswitch (2) in direction of arrow.
Remove heater controls.
Installation:
Clip in microswitch with button (1) towards top.
64 11 ... Removing and installing/replacing air duct for right footwell

Remove insert in front of glovebox and trim below glovebox.
Version with on-board monitor only:
Remove complete on-board monitor.
Note:
Air duct for right footwell (1) is clipped onto housing of heater - A/C unit.
Unlock air duct for right footwell (1) through opening of heater - A/C
controls or on-board monitor.Installation:
Opening (2) for lock must not be damaged.
Lift unlocked air duct for right footwell (1) upwards out of rear
compartment air duct and feed out to front right.
64 11 200 Removing and installing/replacing heater
Warning!
Danger of scalding!

Detach water hoses.
element.
Installation:
Fill and vent cooling system.
Release screws (2) on firewall (1).

Remove center console.
Release shear screw (1) (e.g. mill off or rebore screw head).
Release screw (2).
Release screws and lower steering column.
Release screw.
Detach door weatherseal (1) and trim (2) on A-pillar on left and right.
Unfasten transverse reinforcement on right and left.
Warning!
Follow safety instructions for working on cars with airbag systems.
Release head airbag on transverse reinforcement on right and left.
Disconnect heater plug connections.
Unfasten transverse reinforcement on right and left sides of center

console.
Cut open cable ties (1).

Turn lock (2) on left and right on fuse box through approx. 90° and fold
down fuse box.
Disconnect pivot (1) of fuse box on left and right at transverse
reinforcement towards top.
Remove transverse reinforcement.
Remove heater.
64 11 206 Removing and installing/replacing heater (A/C control)
Remove and install/replace heater (automatic A/C control),

refer to 64 11 205.
64 11 213 Removing and installing/replacing heater - A/C unit fan

51 3 057

E46 and E83:
E46 M43TU only:
E46 M47, M47TU only:
Remove complete wiper console.
E46 M52TU, M54 only:
Remove engine cover.
E46 M57 only:
E46 N42 only:

E46 S54 only:
Detach hose (1) in direction of arrow from fitting (2).
Remove cover strip (3) in direction of arrow from guide (4).
Pull lock (1) in direction of arrow and feed out flap (2).
Unclip retainers (1).
Unscrew bolt (2).
Feed out fan cover (3).
Release screws (1).

Pull out fan cover (2).
Installation:
Make sure fan cover (2) is correctly seated.

Release retainer with special tool 51 3 057 .
Installation:
Bridge (1) must snap into place in opening (2) of fan motor.
Remove fan for heater - A/C unit towards front.Installation:
Make sure fan for heater - A/C unit is correctly seated.
64 11 220 Removing and installing/replacing resistor for heater blower

refer to 51 71 080.
Release screws and lever out cover for blower impeller.
Release screw (1), disconnect plug connection (2) and lever out blower
resistor.Installation:
First install resistor. Then insert plug connection.
64 11 806 Removing and installing/replacing servodrive for right fresh-
air/recirculated-air flap
Removing and installing air duct for right footwell,

Refer to 64 11 ...
Unlock actuator drive (1) and remove towards bottom.
Installation:
If necessary, align shaft for fresh-air/circulating-air flap and drive (see
illustration).
64 11 992 Removing and installing/replacing solar sensor
Remove trim panel for instrument panel.
Unclip cable and pull out solar sensor (1) in direction of arrow.Installation:
Make sure solar sensor (1) is correctly installed and wiring is properly
routed.
64 11 845 Replacing actuator drive of defrosting flaps
Remove and install housing for glovebox and cover on equipment

carrier at bottom,
refer to 51 45 030.
Unlock actuator driveÂ (1) and feed out towards side. Disconnect plug.
Installation:
If necessary, align shaft for defrosting flaps and drive (see
illustration).
64 11 839 Replacing actuator drive of footwell flap

carrier at bottom,
refer to 51 45 030.
Remove and install airbag module on passenger side,
refer to 72 12 000.
Unhook adjusting lever (1).
Disconnect plug connection (1). Unlock actuator drive (2) and feed out
towards rear.
Installation:
If necessary, align shaft for footwell flap and drive (see illustration).
64 11 829 Replacing actuator drive of ventilation flaps

carrier at bottom,
refer to 51 45 030.
Remove and install actuator drive of defrosting flap,
refer to 64 11 845.
Disconnect plug connection (1). Unlock actuator drive (2) and remove.
Installation:
illustration).
64 11 942 Replacing evaporator temperature sensor
Press back heating duct for left footwell (1) in direction of arrow.
Lever out evaporator temperature sensor (2) in direction of arrow and
remove.
Disconnect plug connection (3) and remove evaporator temperature
sensor (2).
Installation:
Ensure evaporator temperature sensor (2) is correctly seated.
64 11 322 Replacing front panel (IHKR)

Important!
Pull off rotary knobs in center positions. Do not turn potentiometers
after removing rotary knobs.
Press down rotary buttons.

Unscrew bolt (1).
Unclip catches with screwdriver and disconnect housing of control

panelÂ (1) from front panel.
64 11 321 Replacing front plate (air conditioner controls)
Caution!
Place heater controls on special tool 12 7 192 (antistatic mat) and
connect to ground.
Release screws (1).
Caution!
Do not touch printed conductors with bare hands (risk of corrosion).
Press locks (1) outwards and remove circuit board (2).

64 11 332 Replacing heater controls (A/C control)
Remove heater controls (climate control).
Note:
64 11 331 Replacing heater controls (automatic air conditioning)
Remove heater controls (automatic A/C).
Note:
64 11 207 Replacing heater core
Remove microfilter housing.

Warning!
Danger of scalding!

Detach water hoses.
element.
Installation:
Filling and bleeding the cooling system,
Withdraw temperature sensor (1). Unclip wiring harness (2).
Release screw (1) and remove bracket (2) from double pipe.
Unclip retainers (3) and lift off cover for heating element (4).
Installation:
First insert lugs (5).
Remove retainers (1) and remove double pipe (2) towards top.
Raise heating element (3) at front and remove.
Installation:
Replace seals.
Coat sealing rings with antiseize agent and ensure correct seating.
64 11 228 Replacing output stage/switch for heater - A/C system blower
Remove air duct for right footwell.
Unhook linkage (2) in direction of arrow.

Release screw (1).
Installation:
Ensure that guide (3) is correctly seated.
Release screw (1).

Unhook holder for actuator drive (2).
Disconnect plug connection on actuator drive (3).

Loosen screws (1).
Undo lock in direction of arrow and remove output stage/switch for heater
- A/C system blower (3).
Installation:
64 11 800 Replacing servodrive on gear for flap control (A/C control)

Remove complete glovebox
Move rotary knob (1) into position illustrated.

Unlock servo-drive (2) and remove towards bottom.
Installation:
illustration).
64 11 939 Replacing temperature sensor for heater (in cover for heating
element)

If necessary, remove on-board monitor.

Remove temperature sensor (2).
64 11 271 Replacing water valve for heater
M43TU, M52TU, M54, S54, N42 only:

Remove intake filter housing.
M47 only:
Remove acoustic cover at front with intake snorkel.
Warning!
Danger of scalding!
M47TU only:
Release hose clamps (2) and detach water hoses.
Lift out water valve for heater (3).
Installation:
If necessary, replace rubber mount.
All except M47TU:
Water valve for heater with auxiliary water pump:

Lift out water valve for heater (3).
Installation:
Water valve for heater without auxiliary water pump:

Withdraw heater valve for heater (3) in direction of arrow from bracket (4).
Installation:
All:
Installation:
64 12 060 Removing and installing complete electric auxiliary heater (flow
heater)
Warning!
Danger of scalding!

Pull vacuum hose (2) and negative lead (3) out of retaining clip and lay to
one side.
Unlock hose holder (4) and lay water hose (5) to one side.
Open cover (1).

Unscrew nuts (2).
Disconnect negative lead (3) and positive lead (4) from electric auxiliary
heater.
Installation:
If necessary, disconnect water hoses.

Installation:
Loosen screws (1).

Remove electric auxiliary heater (2) towards top.
64 12 060 Removing and installing/replacing complete electric auxiliary
heater (flow heater)

Warning!
Danger of scalding!
M47 only:

Open cover (2).
Disconnect negative and positive leads (3) from electric auxiliary heater.
Installation:
If necessary, disconnect coolant hoses .

Release hose clamps (1) and detach coolant hoses.
Installation:
Fill and vent cooling system .

Pull out electric auxiliary heater (3) towards top.
M57 only:
Open cover.
Disconnect negative and positive leads (2) from electric auxiliary heater.
Installation:
Note:
For purposes of clarity, graphic shows auxiliary heater removed.
If necessary, disconnect coolant hoses .

Release hose clamps on electric auxiliary heater and detach coolant
hoses.
Installation:
Fill and vent cooling system .
Release screws (1).

Remove electric auxiliary heater (2).
64 12 061 Replacing complete electric auxiliary heater (flow heater)
Remove and install electric auxiliary heater completely.
64 22 135 Removing and installing / replacing left fresh-air grill
Remove left wood trim.
Loosen screwsÂ (2).

Withdraw fresh air grill in direction of arrow.
64 22 136 Removing and installing / replacing right fresh-air grill
Remove right wood trim.
Loosen screws (1).

Withdraw fresh air grill (2) in direction of arrow.
64 22 162 Removing and installing/replacing center fresh air grill (air
conditioning)
Remove decorative strip above radio,

refer to 51 16 221.
Release screws (1). Press fresh air grill from bottom to top and twist out
backwards.
Pull off clip (1) upwards. Release Bowden cable (2) with pliers and pull
out. Turn eye (3) upwards and slide to right.
64 22 161 Removing and installing/replacing center fresh air grill (heating)

refer to 51 16 221.
Release screws (1). Press fresh air grill from bottom to top and twist out
backwards.
64 31 010 Replacing microfilter for interior ventilation
Turn toggle (1) through approx. 90 Â° and remove cover (2) towards
front.
Remove microfilter element (1).

64 50 ... A/C performance test
Observe the following conditions prior to the A/C performance test:
1. Connect diagnosis system. Check of the fault memory (no faults in the fault memory).
2. Attach a thermometer with separate display element to the head restraint. Lay display element outwards
out of passenger compartment.
3. Perform the test in a suitable workshop area with an ambient temperature above 18° C.
4. Vehicle temperature should be approximately the same as the ambient temperature in the workshop.
5. Engine must be at operating temperature (does not apply for electric vehicles).
6. ECO PRO mode must not be switched on.
Heat passenger compartment:

”A/C button” is not activated during the heating process
Close all side windows and doors
Set air recirculation function.
Select air distribution mode for footwell and defrosting.
On vehicles with CID: In A/C menu (CID) in Air distribution index tab: select 100 % footwell for driver and
front passenger and 100 % defrosting for driver (this applies here to driver and front passenger)
Maximum temperature setting
Maximum blower speed
Start engine (does not apply for electric vehicles)
Cool down passenger compartment:
Switch on air conditioning compressor with "A/C button" at a vehicle interior temperature of 45 °C (measured at
the head restraint).
On vehicles with MAX‐AC button:
Activation of MAX‐AC (= maximum cooling power)
On vehicles without MAX‐AC button:

Set maximum cooling power by means of following steps:
Setting minimum temperature
Blower setting maximum
Stratification maximum cold (4 blue bars)
Only ventilation open
Close remaining flaps (air outlet only from centre fresh air grille, left and right)
After 5 min, measure both ventilation temperatures with a thermometer at the same time (centre, left and right
fresh air grille). The measured temperature must be ≤ 16 °C and the difference between right and left may not
be greater than 2 °C.
If one or both temperature specifications is not reached drain off heating and air conditioning system. Measure
the amount of refrigerant drawn off and compare with the nominal fill amount.
Check whether refrigerant loss is present:
If there is a permissible loss of refrigerant, fill the refrigerant circuit with the nominal fill amount.
If there is an impermissible loss of refrigerant, check the refrigerant circuit for tightness. After rectifying the
leak, fill the refrigerant circuit with the nominal fill amount.
If there is no refrigerant loss, continue troubleshooting using the pressure measurement (only possible
for vehicles with unregulated air conditioning compressor up to series E46/E53).
64 50 010 Drawing off, evacuating and filling air conditioning (R134a)
Warning!
Only persons in possession of a professional certificate of
competence for the maintenance and repair of heating and air
conditioning systems are authorised to carry out repair work on the
refrigerant circuit. It must be available no later than 04 July 2010
(applies only to EU countries; follow country-specific regulations in
non-EU countries).
Refrigerant circuit is under high pressure!
If the protective caps on the filling valves are difficult to open,
there is a danger of injury from leaking valve inserts.
Repair work may only be carried out on a depressurised refrigerant
circuit!
Before conducting repairs, check the actual pressure drop on
the pressure gauge of the A/C service station.
Avoid contact with refrigerant and refrigerant oil.
Follow safety information for handling R 134a refrigerant.
Follow safety information for handling refrigerant oil.
Attention!
The suction-side filling line of the refrigerant circuit is omitted from
the engine versions of model series E9X and E8X.
This is replaced by a direction connection on the expansion valve.
Changeover time frame:

From 07/09 - N54
From 08/09 - N43
Until end of 2009 - all other engine versions except N45/N46
and S65
Shown on N54 engine by way of example.

Direct connection of filling adapter (1) on the expansion valve is shown.
Note:
Make sure filling hose (1) is laid without kinks.
Note:
N52 engine only:
On vehicles with hydraulic steering (e.g. AFS) oil reservoir (1) must be
detached.
Refer to: Remove oil reservoir for hydraulic steering
Attention!
Risk of damage!
Only BMW-approved R134a refrigerant may be used. ( refer to
sourcing reference: Operating Fluids)
Restart engine only when the air conditioning system has been
correctly filled.
Attention!
Risk of damage!
Carefully move the climate service station!
Comply with the operating instructions and service interval for the
A/C service station!
Make sure that the hoses of the A/C service station are drained
after the drawing off or filling procedure!
The climate service station contains highly sensitive components,
such as scales. These components will be damaged due to
improper handling, such as fast driving over a bump. This will result in
a significant reduction of the measuring accuracy when drawing off
and filling.
Attention!
The vehicle must be parked on the floor during all drawing off,
evacuation and filling procedures!
Filling a raised vehicle will result in insufficient filling levels.
Note:
In case of complaints, carry out a heating and air conditioning
performance test!
If the system fails the test, draw off, evacuate and fill the heating and air
conditioning system in accordance with the operating instructions of the
relevant service station.
Service interval of service station must be adhered to.
E60 only:
If necessary, to connect service station, use manufacturer's adapter for
high-pressure connection (red).
Instructions for drawing off heating and air conditioning system:
To help separation of refrigerant and refrigerant oil, run engine at low

speed (800-1200 rpm) and with heating and air conditioning system
turned on for a few minutes.
The limits the entrainment of refrigerant oil while it is drawn off.
Drawn-off refrigerant oil must be changed and reintroduced via the
service station.
During drawing off, set the blower of the heating and air-conditioning unit
to the middle blower speed. This ensures that drawing off is more
effective since the pressure on the low pressure side increases.
Recycling:
Dispose of drawn-off refrigerant oil as hazardous waste.
Attention!
E72 only:
Vehicle must be evacuated from both sides!
Instructions for evacuating heating and air conditioning system:
Before each filling, evacuate the refrigerant system.

Observe an evacuation time of at least 30 minutes.
The evacuation procedure removes all traces of ambient air, water
vapour and any other gases present from the heating and air
conditioning system. This enables subsequent system filling with
refrigerant.
If the vacuum does not remain stable when the system is off, run the
procedure for leaks in the refrigerant circuit.
During evacuation, set the blower of the heating and air-conditioning unit
to the middle blower speed. This ensures that evacuation is more
Instructions for filling heating and air conditioning system:
Before filling with refrigerant, replace the refrigerant oil entrained during
drawing off.
Also top up any lost fluid as indicated in the table:
Loss of R134a refrigerant
Table 1 indicates the permitted loss of refrigerant after a specific period
of time. There is no leak. Refrigerant oil must not be topped up.
Table 2 indicates the amount of refrigerant oil must be topped up with an
unapproved loss of refrigerant due to a leak after a specific period of
time.
Different cases:
a. Loss of refrigerant per Table 1 is not exceeded
Top up lost R134a refrigerant
It is not permitted to top up the refrigerant oil
b. Loss of refrigerant per Table 1 is exceeded
Top up lost R134a refrigerant
refrigerant oil must be topped up additionally per Table 2
Table 1: 0-1 1-2 2-3 3-4 4-5

Number of years since last filling
Permissible loss [g] --> Do not top up ≤ 30 ≤ 60 ≤ 90 ≤ 120 ≤ 150

refrigerant oil
Table 2: R134a loss of Top up quantity

Number of years since coolant [g] refrigerant oil
last filling
0 -1 - <120 0
120 - 150 10
> 150 20
1-2 - <180 0
180 - 210 10
> 210 20
2-3 - <240 0
240 - 270 10
> 270 20
3-4 - <300 0
300 - 330 10
> 330 20
4-5 - <360 10
> 360 20
Follow instructions for opening and part replacement in refrigerant circuit.

Depending on the type of component replaced on the heating and air
conditioning system, it may be necessary to the top up the refrigerant oil,
even if no measurable losses have occurred during drawing off. Follow
the notes provided by the heating and air conditioning system
manufacturer, taking account of the tolerances (and inaccuracies)
indicated in the operating instructions of the relevant service station.
Information on the required refrigerant fill quantity for the entire heating
and air conditioning system is contained on the type plate (1) in the
engine compartment.
If necessary, refer to the Technical Data for capacity.
Installation note:
Reseal refrigerant filler necks on vehicle with sealing caps.
64 50 010 Drawing off, evacuating and filling heating and air conditioning
system (R1234yf)
Warning!
Only persons in possession of a professional certificate of
competence for the maintenance and repair of heating and air
conditioning systems are authorised to carry out repair work on the
refrigerant circuit. It must be available no later than 04 July 2010
(applies only to EU countries; follow country-specific regulations in
non-EU countries).
If the protective caps on the filling valves are difficult to open,
there is a danger of injury from leaking valve inserts.
Repairs may only be carried out on a depressurised refrigerant
circuit!
Before conducting repairs, check the actual pressure drop on
the pressure gauge of the A/C service station
Observe safety information for handling refrigerant R1234yf
Follow safety information for handling refrigerant oil.
Attention!
Risk of damage!
Only BMW-approved R1234yf refrigerant may be used (refer to
sourcing reference: Operating Fluids).
Restart engine only when air conditioning has been correctly filled.
Vehicle-specific notes:
Only I01:
To access the connections for the refrigerant lines, remove front

luggage compartment well.
Only I12:
Attention!
Risk of damage!
Risk of paint damage and scratches!
Open engine compartment lid to access the connections of
the refrigerant lines.
Open and close the engine compartment lid as specified
in the instructions without exception!
BMW i, Plug-in Hybrid Electric Vehicle and vehicles with rear

passenger compartment air conditioning:
To ensure almost full draining of the refrigerant circuit or the

hybrid battery cooling system, run the following test module:
Body
Air conditioning function
Drain / fill the refrigerant circuit
Drain/fill the refrigerant circuit (without I01 with heat pump)
Drain/fill the refrigerant circuit of the heat pump (I01 with heat
pump)
After filling the refrigerant circuit, delete the fault memory.
Attention!
For R1234yf, an A/C service station especially suited for this
refrigerant must be used!
A/C service station for R134a must not be used!
Comply with the notes on refrigerant (R134a, R1234yf) and
refrigerant oil (Sanden SP-A2).
Risk of damage!
Carefully move the climate service station!
Comply with the operating instructions and service interval for the
A/C service station!
Make sure that the hoses of the A/C service station are drained
after the drawing off or filling procedure!
The climate service station contains highly sensitive components,
such as scales. These components will be damaged due to
improper handling, such as fast driving over a bump. This will result in
a significant reduction of the measuring accuracy when drawing off
and filling.
Attention!
The vehicle must be parked on the floor during all drawing off,
evacuation and filling procedures!
Filling a raised vehicle will result in insufficient filling levels.
Note:
Perform A/C performance test in event of customer complaint!
If the system fails the test, draw off, evacuate and fill the air conditioning
in accordance with the operating instructions of the relevant service
station.
Instructions for drawing off air conditioning:

Before evacuation, the A/C service station will investigate the refrigerant.
If the refrigerant is consistent with the requirements, evacuation is
continued.
If the refrigerant fails to meet the requirements, then a special procedure
must be complied with when drawing off and disposing of this refrigerant.
In order to enhance the separation of refrigerant and refrigerant oil,

allow the Air conditioning to run for a few minutes before drawing off.
The limits the entrainment of refrigerant oil while it is drawn off.
Drawn-off refrigerant oil must be changed and reintroduced via the A/C
service station.
During drawing off, set the blower of the heating and air-conditioning unit
to the middle blower speed. This ensures that drawing off is more
Recycling:
Note in case of contaminated refrigerant R1234yf:
If the A/C service station for R1234yf refrigerant identifies contaminated
refrigerant in the refrigerant circuit of the vehicle before evacuation, then
a special procedure to draw off and dispose of this refrigerant must be
followed.
Instructions for evacuating off air conditioning:
Before each filling, evacuate the refrigerant circuit.

Observe an evacuation time of at least 30 minutes.
The evacuation procedure removes all traces of ambient air, water
vapour and any other gases present from the heating and air
conditioning system. This enables subsequent system filling with
refrigerant.
If the vacuum does not remain stable when the system is off, run the
procedure for leaks in the refrigerant circuit.
During evacuation, set the blower of the heating and air-conditioning unit
to the middle blower speed. This ensures that evacuation is more
Notes for filling heating and air conditioning system:
In certain cases, Sanden SP-A2 refrigerant oil must be injected into the
Before filling with refrigerant, replace the refrigerant oil entrained during
drawing off.
Also top up any lost fluid as indicated in the table:
Loss of R1234yf refrigerant
Table 1 indicates the permitted loss of refrigerant after a specific period
of time. There is no leak. refrigerant oil may not be topped up.
Table 2 indicates the amount of refrigerant oil must be topped up with an
unapproved loss of refrigerant due to a leak after a specific period of
time.
Different cases:
a. Loss of refrigerant per Table 1 is not exceeded
Top up lost R1234yf refrigerant
It is not permitted to top up the refrigerant oil
b. Loss of refrigerant per Table 1 is exceeded

Top up lost R1234yf refrigerant
refrigerant oil must be topped up additionally per Table 2
Table 1: 0-1 1-2 2-3 3-4 4-5

Number of years since last filling
Permissible loss [g] --> Do not top up ≤ 30 ≤ 60 ≤ 90 ≤ 120 ≤ 150
refrigerant oil
Table 2: Loss of R1234yf Top up quantity
Number of years since refrigerant [g] refrigerant oil
last filling
0 -1 < 120 0
120 - 150 10
> 150 20
1-2 < 180 0
180 - 210 10
> 210 20
2-3 < 240 0
240 - 270 10
> 270 20
3-4 < 300 0
300 - 330 10
> 330 20
4-5 < 360 10
> 360 20
Follow notes for opening and replacing parts in refrigerant circuit.

Depending on the type of component replaced on the heating and air
conditioning system, it may be necessary to the top up the refrigerant oil,
even if no measurable losses have occurred during drawing off. Follow
the notes provided by the air conditioning manufacturer, taking account
of the tolerances (and inaccuracies) indicated in the operating
instructions of the relevant service station.
Information on the required refrigerant capacity for the entire air
conditioning is contained on the type plate (1) in the engine
compartment.
If necessary, refer to the Technical Data for capacities.
Installation note:
Reseal refrigerant filler necks on vehicle with sealing caps.
Warning!
Important!
Warning!
is inflammable.
(high pressure).
station
damage.
Installation note:
64 50 ... Instructions for handling refrigerant oil (for refrigerant R 134a)
Warning!
Observe the following points when handling refrigerant oil:
Wear protective goggles.
Wear protective gloves made from impermeable plastic.
Do not swallow.
Do not inhale.
Action to be taken after contact with refrigerant oil:
After contact with eyes, rinse thoroughly with plenty of water
and take out contact lenses (if worn). Then seek immediate
medical attention.
After contact with the skin, wash body parts affected with
plenty of soap and water.
Do not induce vomiting if oil is swallowed, seek immediate
medical attention.
If inhaled, introduce the person affected to fresh air. Seek
medical attention if problems persist.
Warning!
refrigerant oil is non-combustible and non-explosive at normal
temperatures. In spite of this, the following precautions must be
observed:
Do not store in the vicinity of flames, heat sources or strongly
oxidising materials.
Suitable extinguishants: Carbon dioxideÂ (CO2), dry
extinguishant, foam.
Important!
refrigerant oil is hygroscopic and must therefore be stored in
suitable containers that are sealed airtight!
Recycling:
Absorb escaping refrigerant oil with fluid-binding material.
Notify the relevant authorities if larger amounts of refrigerant fluid are
discharged into aboveground water supplies, drainage systems or
subsoil.
64 52 ... Instructions for opening and part replacement in refrigerant
circuit
00 9 030
32 1 270
Warning!
Avoid contact with refrigerant and refrigerant oil
Follow safety information for handling R134a refrigerant
Follow safety information for handling refrigerant oil
Attention!
Always use new O-rings each time A/C connections are opened (refer to Electronic Parts Catalogue)
They must not be coated.
Use special tool 00 9 030 to install sealing rings without damaging them.
Open the referigerant circuit for as short of a period as possible.
Close all components and lines in the refrigerant circuit and return parts immediately following the
removals at openings with special tool 32 1 270 to prevent penetration of moisture or foreign objects.
If the refrigerant circuit was closed at the openings with special tool 32 1 270 but it remains open for more
than 24 hours, the dryer insert for the air conditioning must be replaced.
I. Part replacement as preliminary work fur further repair work and based on gradual leakage.
(minor leak, e.g. hairline crack)
Procedure:
Draw off heating and air conditioning system, then determine drawn-off amount of refrigerant
Carry out part replacement
Replace removed refrigerant oil and additionally top up with new refrigerant oil according to
components replaced:
Compressor: refer to Notes on compressor replacement
Evaporator: 10 ml
Capacitor: 20 ml
Desiccant insert / dryer flask: 20 ml
Each replaced refrigerant line: 10 ml
Capacitor with integrated dryer: 40 ml
Safety pressure switch and gasket: no additional refrigerant oil
Evacuate and fill A/C system
II. Part replacement due to sudden leakage

(major leak, e.g. pipe break due to accident)
Procedure:
Replace removed refrigerant oil and additionally replace with new refrigerant oil according to parts
replaced:
Evaporator: 35 ml
Capacitor: 35 ml
Attention!
Note:
condenser (2-6).

64 50 ... Leak detection with forming gas
Note:
Leak detection with forming gas replaces the leak detection that is
restricted in EU countries using UV.
Observe national regulations in all other countries!
Attention!
Compliance with the manufacturer's operating instructions provided
in the equipment case is absolutely mandatory!
Comply with SI 08 08 10 (670)!
Read and comply with the manufacturer's operating instructions
provided with the special tool particularly with regard to accident
prevention, health protection and environmental protection.
Only the basic procedure is described in the following!
Attention!
Wear personal protective clothing/equipment!
Note:
Determine the customer's use behaviour prior to leak detection!
Certain user behaviours can lead to a loss of refrigerant from the
refrigerant circuit even if there is no leak. This may occur if the customer
has not used the air conditioning for a period of more than six months.
This may cause O-rings to harden and refrigerant may escape. In this
case, it will be sufficient to fill the refrigerant circuit again and switch on the
air conditioning for approximately 10 minutes while the engine is running.
If components of the refrigerant circuit are contaminated, clean
the engine compartment. Otherwise, the sensor head of the leak
detector will become contaminated.
Comply with notes and instructions on handling high pressure
cleaner.
Drain off air conditioning system
Fill the air conditioning with forming gas
Set pressure to 5 bar
To reach the components of the refrigerant circuit with leak detector,

specific parts must be removed depending on the vehicle.
Remove the following parts first immediately before the check of the
respective components:
Drive belt from air conditioning compressor
Centre fresh air grille
Covers
Trim panels
Air duct
Intake silencer
Bulkheads
Parts of the interior equipment (automatic rear air-conditioning
system)
In some vehicles it is necessary to open the air flaps of the automatic air
flap control.
Vehicle-specific notes:
Only I01:
To access the connections for the refrigerant lines, remove front

luggage compartment well.
Only I12:
Attention!
Risk of damage!
Risk of paint damage and scratches!
Open engine compartment lid to access the connections of
the refrigerant lines.
Open and close the engine compartment lid as specified
in the instructions without exception!
Only BMW i and hybrid vehicles:
To ensure almost full draining of the refrigerant circuit or the

hybrid battery cooling system, run the following test module:
Body
Air conditioning function
Drain/fill refrigerant circuit of heat pump (onlyI01 with heat
pump)
Delete fault memory after filling refrigerant circuit.
Attention!
Always perform the leak detection with a pressure of 5 bar at first!
This is absolutely necessary to find certain leaks, such as in the
area of the O-rings.
If no leak is detected, repeat the leak detection with 10 bar.
Attention!
The leak detection may not be performed more than 3 h after filling
the refrigerant circuit with forming gas!
Forming gas consists of 95% nitrogen and 5% hydrogen. The leak
detector will detect hydrogen. If this is leaking from the refrigerant
circuit even though the pressure remains, the leak detection bears
no results.
Attention!
Risk of damage!
Maximum approved pressure: 10 bar
Do not start the engine during the entire procedure!
Notes for handling the leak detector:

1. Sensor head should always stand vertical to the surface to be checked.
2. Sensor head must always be aligned to the centre of the point to be checked. Slowly guide the sensor head around
the point (e.g. connection point, sealing surface, etc.).
3. The optimal distance (A) between sensor head and surface to be checked should permanently be approximately 1
mm.
Maximum distance (B) at points that are difficult to access approximately 5 mm.
4. Checking speed may not be more than maximum 2 cm per s.
Note:
If the leak detector displays a leak, remove the sensor head from the leak for approximately 10 s.
Then check if the leak is still displayed at the same point. Repeat the process up to three times,
to ensure that a leak is actually present at this point.
Note:
Replace the leaking component. Relieve the pressure from the refrigerant circuit prior to replacement.
Attention!
Compliance with the instructions above is absolutely mandatory!
Non-compliance will significantly reduce the efficiency of leak detection!
Note:
The graphic shows the example of the refrigerant circuit on the F02 with the
automatic rear air-conditioning system optional equipment .
Refrigerant circuits on other vehicles may differ from the graphic.
Refrigerant circuits of BMW i vehicles differ a lot from the figure:
Overview components refrigerant circuitI01
Overview components refrigerant circuitI12
Note additional components during leak detection in these vehicles!
Overview of positions to be checked:

1. Air conditioning condenser
2. Connection point between air conditioning condenser and refrigerant line
3. a) Expansion valve, front (vehicles with and without automatic rear air-
conditioning system)
b) Expansion valve, rear (vehicles with automatic rear air-conditioning system)
4. Air conditioning compressor
5. Filler neck high pressure and low pressure
6. Refrigerant pressure sensor
7. a) Refrigerant line, front (vehicles with and without automatic rear air-conditioning
system)
b) Refrigerant line, rear (vehicles with automatic rear air-conditioning system)
8. a) Evaporator, front (vehicles with and without automatic rear air-conditioning
system)
b) Evaporator, rear (vehicles with automatic rear air-conditioning system)
Note:
Refrigerant line connection points are identified by arrows.
Checking sequence:
1. Check of components 1, 2, 3a, 4, 5, 6, 7a and 8a of the automatic
front air-conditioning system.
If no fault found:
2. Check of components 3b, 7b, 8b and connection points of the
automatic rear air-conditioning system.
1. Air conditioning condenser:

Damage caused by stone chipping, etc. is the most frequent cause of air
conditioning condenser leaks (1):
1. Visual inspection in the area of the radiator grille (2) and air inlet
grille, centre (3).
2. Check damaged points first.
3. Check the remainder of the air conditioning condenser.
2. Connection point capacitor - refrigerant line

Check the connection point between the connection at the air
conditioning condenser (1) and refrigerant lines (2).
3. Expansion valve:
Check the connection point between the expansion valve (1) and
refrigerant lines (2).
4. A/C compressor:
Remove drive belt from air conditioning compressor.
Check the following components on the air conditioning compressor:
1. High-pressure connection
2. Low pressure connection
3. Pressure relief valve
4. Radial shaft seal of the magnetic coupling: Turn the magnetic
coupling several times by hand during the leak detection.
5. Filler neck
Blow out the fuel filler neck (1) prior to checking.
6. Refrigerant pressure sensor

Check the sealing surface between the refrigerant pressure sensor (1)
and the refrigerant line (2).
7. Refrigerant lines:
1. Perform visual inspection
2. Check damaged points first.
3. Check bending points at points marked with an arrow. Leaks occur
especially frequently at these points.
4. Check the remainder of the refrigerant line.
8. Evaporator:
Remove the centre fresh air grille.
Compliance with the following settings is absolutely required:
Air recirculation function On
Lowest blower speed
Lowest temperature
Set the air distribution to ventilation (air may only flow out of the
centre fresh air grille)
Position sensor head (1) in air duct of middle fresh air grille (2) as
illustrated and move slowly from inside to outside above and below air
flap (3). Carry out this operation on the left and right fresh air grilles.
Attention!
Some vehicles have an expansion valve directly next to
the fresh air intake for the passenger compartment.
In this case the expansion valve must be covered!
Following the completed leak detection:

Evacuate and fill heating and air conditioning system
64 50 ... Leak detection with ultraviolet additives (UV additives) (BMW leak-
testing case)
Leak detection using ultraviolet additives is generally not

recommended as the UV additives lead to an uncontrolled over oiling
of the refrigerant circuit. This results in a reduction of the cooling
power. Leak detection with forming gas is preferable.
Leak detection using ultraviolet additives is permitted for refrigerants
R134a and R1234yf.
Attention!
In EU countries it is prohibited by law to fill a knowingly leaking
refrigerant circuit with the refrigerants (R134a and R1234yf):
If a leak is suspected in the refrigerant circuit, refilling with
refrigerant and UV additives for the purpose of a subsequent
leak detection is not permitted
In this case carry out leak detection with forming gas
UV additives must be filled only in a tight refrigerant circuit
Observe national regulations in all other countries!
Attention!
It is absolutely essential to read and comply with the equipment
manufacturer's operating instructions provided in the leak testing
case!
Read and comply with the manufacturer's operating instructions
provided with the leak testing case with regard to accident
prevention, health protection and environmental protection.
Use only BMW-approved UV additives (e.g. TRACER).
Only the basic procedure is described in the following!
Attention!
UV additives may not be used in vehicles with electric A/C
compressors!
Warning!
Avoid contact with refrigerant.
Follow safety precautions when handling refrigerant.
Attention!
Ultraviolet lamp gets very hot in the radiation area!
Do not use the ultraviolet lamp without the filter glass.
Eyes and skin will suffer damage if the ultraviolet lamp is used
without the filter glass.
When using the UV lamp, wear the safety goggles provided in the
case.
Note:
Fill the hose system of the hand pump completely with UV additive
PRIOR to use
Use the UV additive exclusively for refrigerant oil approved by BMW
Do not operate the air conditioning while the hand pump is
connected or in use
The air conditioning must always be filled with an adequate amount
of refrigerant to enable the UV additives to be properly distributed

Before actually testing for leaks, check the entire refrigerant circuit
using the UV leak detection lamp to ensure that no UV additive is
already in the area of the refrigerant circuit.
If already illuminated areas are found, carefully clean the area in
question with the cleaning agent contained in the leak testing case.
On initial use:
Connect hand pump (1) to additive cartridge (2) and pipe section (3).
On initial use:
Attach vent valve (1) to quick-release coupling (2).
Turn handle (3) on hand pump to advance the piston until a small amount
of UV additive emerges. This vents the hose system.
Attention!
The entire hand pump with hose system must not be disassembled
again once filling has been completed.
Attach quick-release coupling (1) to low-pressure connection (2) of air
conditioning system.
Turn handle on hand pump (3) until the required amount of UV additive is
added.
The quantity of UV additive to be added is dependent on the amount of
refrigerant in the refrigerant circuit:
Air conditioning systems with refrigerant filling up to 900 g: one
graduation mark (4) on additive cartridge
Air conditioning systems with refrigerant filling in excess of 900 g:
two graduation marks (4) on additive cartridge
Note:
After filling remove the quick-release coupling (1). If necessary, clean the
areas with contaminated with UV additive using the cleaning agent
contained in the leak testing case.
Further tasks:
Start engine
Run air conditioning at highest level for 5 - 10 minutes in order to
ensure adequate distribution of dye in the system
Turn off engine.
Check all components of the refrigerant circuit for possible leaks
Possible leaks are displayed in luminous green
Complete accompanying information label (1) with the relevant data and
attach in an easily visible position next to the type plate (2).
Attention!
are used.
bonnet.

Europe Asia America

Herzegovina
Netherlands
Korea
Republic
models have R134a.

BMW i as of 09/2013
USA and Canada:
South Korea:
and model.

Attention!
Attention!
Exception:


procedure!
Warning!
Danger of injury!

Wear safety goggles
Do not smoke!
First aid measures:

ophthalmologist.
64 50 ... Safety informations for handling refrigerant oil
Warning!
Danger of injury!
The refrigerant circuit is depressurised AFTER drawing off!

Wear safety goggles
Do not smoke!
First aid measures:

If swallowed: Do NOT induce vomiting, unless expressly instructed
to do so by medical personnel. Do not administer anything to an
unconscious person through their mouth. Consult a doctor
immediately if larger quantities of this substance are swallowed.
Loosen tight-fitting items of clothing (e.g. collar, tie, belt or similar).
Eye contact: Remove contact lenses if worn. In the event of eye
contact, rinse eyes for at least 15Â minutes with plenty of water. It is
essential to use WARM WATER. Consult a doctor.
Skin contact: In the event of skin contact, rinse immediately with
plenty of water. Remove contaminated clothes and shoes. Wash
affected clothes before wearing again. Clean shoes thoroughly
before reusing. Call for a doctor.
After inhalation: If inhaled, take the person affected outside into
fresh air immediately and keep them under supervision. Call for a
doctor. If breathing difficulties are experienced, administer additional
oxygen. If the person affected stops breathing, administer the kiss
of life.
Recycling
Catch and dispose of emerging refrigerant oil.
64 50 ... Safety informations for handling tetrafluorethane refrigerant R134a
Warning!
Danger of injury!
The refrigerant circuit is depressurised AFTER drawing off!

Wear safety goggles
Do not smoke!
First aid measures:

ophthalmologist.
64 50 ... Troubleshooting by pressure measurement (R 134a)
Note:
The troubleshooting by pressure measurement described in the
following is only possible on A/C systems with uncontrolled
compressors.
This includes among others:
E53
E46M47 up to 09/2001
E38 up to 09/1997
E36, E36/7
E34
E32
E31
Connect service station to car and open both valves on the charging
hoses. Adjust A/C system at control panel as described for A/C
efficiency measurement.
Note:
The following values apply as normal pressure ranges for ambient
temperatures between + 20°C and + 40°C:
Inlet pressure: 1.0 - 2.2 bar
Outlet pressure: 12 - 22 bar
Normal inlet pressure and high outlet pressure indicate an overfilled

system, a contaminated condenser or a faulty auxiliary fan.
Remedy:
Draw off, evacuate and refill A/C system. Clean condenser from outside,
check auxiliary fan, replace if necessary.
High inlet pressure and low outlet pressure indicate a faulty compressor.
Remedy:
Replace compressor.
Compressor does not run with equal inlet and outlet pressures.
Remedy:
If the anti-icing facility has shut down the compressor, check evaporator
sensor and power supply to clutch. Otherwise check clutch mechanically
(by slipping).
Normal inlet pressure and low outlet pressure indicate an insufficient fill
quantity of refrigerant.
Remedy:
1. Draw off and measure refrigerant.
2. If the amount drawn off corresponds approx. to the specified fill
quantity, check expansion valve for unobstructed throughflow;
3. Then evacuate and refill A/C system.
Low inlet pressure and high outlet pressure can be caused by a variety
of factors:
Icing of evaporator
Remedy: Check evaporator sensor, replace if necessary.
Obstruction on H.P. side after condenser or on L.P. side
Remedy:
Check drier, expansion valve and pipes in these areas for
unobstructed throughflow; clean or replace if necessary.
Low inlet pressure and high outlet pressure indicate an obstruction in the
condenser area.
Remedy:
Check condenser for unobstructed throughflow; clean or replace if
necessary.
64 51 001 Cleaning evaporator

64 1 451
64 1 456
64 1 457
64 1 458
Warning!
When handling cleaning agent, observe following protective
measures:
Wear protective rubber gloves and protective goggles.
If cleaning agent comes into contact with eyes or skin, wash
immediately with lots of water.
Important!
To avoid dirtying vehicle interior:
Close all air vents.

Switch heating and air-conditioning unit to air recirculation function.
Cover carpet in working area.
Recycling:
Carry out the cleaning operation in a suitable washing bay as the
emerging cleaning agent escapes through the drain openings in the
transmission tunnel.
Note:
For more notes on the cleaning agent, see Service Information.
For more information on the spraying equipment, see Service
Information on Special Tools/Equipment.
Note:
Ensure that the cleaning agent can flow away freely at the drain
openings. If necessary, remove rear underbody protection.
Remove limit-position switch for air conditioning blower.

Fasten adapter for spraying lance 64 1 457 using screws (1) of limit-
position switch for air conditioning blower.
Close opening (B) with seal plug for adapter 64 1 458 .
Insert spraying lance 64 1 451 in direction of arrow and fasten with

mounting for spraying lance 64 1 456 .
Insert travel limiter (1) into notch (2) of spraying lance 64 1 451 and turn
approx. 45°.
Connect spraying lance 64 1 451 with spraying equipment.

By moving the spraying lance 64 1 451 back and forth, uniformly apply the
cleaning agent to the evaporator.
For information on cleaning agent and rinsing again, refer to Service
Information.
Note:
After completing cleaning, allow car to drip-dry for approx. 5 minutes.
Set heating and air-conditioning unit to footwell ventilation and fresh air
mode. Open windows or doors.
Start the vehicle and let the heating and air-conditioning unit run for at
least 5 minutes at maximum blower output.
Note:
In order to eliminate the last remnants of cleaning agent, repeat this
process shortly before handover to the customer.
64 51 002 Cleaning evaporator (automatic climate control)
Cleaning evaporator.
circuit
00 9 030
32 1 270
Warning!
Attention!
Procedure:
Evaporator: 10 ml
Capacitor: 20 ml

Procedure:
replaced:
Evaporator: 35 ml
Capacitor: 35 ml
64 51 ... Leak-testing condenser

00 9 030
64 5 121
64 5 122
64 5 123
Warning!
Risk of injury!
Follow safety instructions for handling refrigerant
Comply with the standard national safety instructions and
precautions on handling nitrogen.
Ensure that employees are advised of how to handle pressurised
vessels and nitrogen correctly (danger of asphyxiation). For this
purpose, follow the notes and instructions in the technical safety
specifications available from the gas supplier.

Detach refrigerant lines from condenser
E70 only:
Important!
Risk of damage!
Special tool 64 5 122 and special tool 64 5 123 have different
diameters (A, B) at the seal plugs!
Ensure correct connection assignment on condenser.
Fit and secure sealing adapter 64 5 123 to connection of low-pressure
line.
Fit and secure test adapter 64 5 122 to connection of high-pressure line.
E70 only:
Connect special tool 64 5 122 to special tool 64 5 121 .
Important!
Risk of damage: Use only nitrogen pressure bottles with pressure
reducers for leak-testing.
Pressurize condenser to 10 bar slowly only. Excessively fast
pressurization and pressures in excess of 20 bar may cause
damage to the condenser.
Connect nitrogen pressure bottle with pressure reducer to pressure

gauge and then connect to special tool 64 5 121 (connecting hose).
Note:
Testing apparatus must be leakproof.
Ambient temperature and temperature of vehicle must not change
during the test procedure.
Do not move the vehicle during this period
Apply test pressure of 10 bar slowly and close nitrogen pressure bottle.
Check leak-tightness of testing apparatus and of connection to
refrigerant line.
Set test pressure of 10 bar is only permitted to drop by 2 bar to 8.5 bar
over a test period of 1.5 hours.
If the pressure loss is greater than 1.5 bar, this indicates that there is a
leak in the condenser unit.
Warning!
After leak-testing, unscrew special tool 64 5 121 slowly from
special tool 64 5 122 to reduce pressure.
After leak-testing:
Replace sealing rings. Use special tool 00 9 030 to mount sealing
rings without damaging them.
Assemble A/C system
64 51 ... Leak-testing evaporator

64 5 121
64 5 125
Warning!
Comply with the standard national safety regulations on handling
nitrogen.
vessels and nitrogen gas correctly (danger of asphyxiation). For
this purpose, follow the notes and instructions in the technical
safety specifications available from the gas supplier.

Remove expansion valve
Replace sealing rings (1) and coat with refrigerant oil.
Connect special tool 64 5 125 to retaining clamp and screws of

expansion valve.
Important!
Pressurise evaporator to 10 bar slowly only. Excessively fast
pressurisation and pressures in excess of 20 bar may cause
damage to the evaporator.
Note:
Testing device must be leakproof.
during the test procedure
Check leak-tightness of testing device and of connection to refrigerant
line.
leak in the evaporator unit.
Warning!
After leakage check, unscrew special tool 64 5 121 slowly from
After leak-testing:
Replace all sealing rings and coat with refrigerant oil
This documentation refers to special tools that were not yet available when going to press.
64 51 580 Perform leakage test for evaporator
WARNING
Hot surfaces.
Risk of burning!
Perform all work only on components that have cooled down.
CAUTION
Refrigerant circuit under high pressure.
Danger of injury!
Note and follow safety information on containers.
Avoid contact with refrigerant; wear safety goggles and protective gloves.
For more information see: 64 50 Handling refrigerant and 6450 Notes on repair work on air conditioning
PRELIMINARY WORK
1 – Drawing off the air conditioning

See additional information.
MAIN WORK
2 – Perform leakage test for evaporator

Prerequisite
The vehicle must be cooled down. Ambient temperature and temperature of vehicle must not change during the test
procedure. The vehicle must not be moved during the test procedure. Testing device must be tight.
WARNING
Pressure vessel with nitrogen.
Danger of injury! Risk of asphyxiation!

Ensure there us sufficient ventilation in the surrounding area and protect the pressure vessel against overheating.
Note information in safety data sheet for nitrogen.
Install the new sealing rings with special tool 0 496 714 (00 9 030) without
damaging them.
Secure special tool with the expansion valve retaining clip with on-board
screws (1).
Connect special tool 0 496 223 (64 5 121) to special tool .
Connect nitrogen pressure cylinder with pressure reducer to pressure

gauge.
Connect special tool 0 496 223 (64 5 121) to pressure reducer.
Slowly apply test pressure of maximum 10 bar.
Close nitrogen pressure cylinder.
Check
Check tightness of the testing device and of the connection to the
refrigerant circuit by means of e.g. soapy water.
Result
» Leak was detected.
Measure
Seal the connections prior to the leakage test of the evaporator.
Check
Evaporator is tight if the adjusted test pressure of 10 bar drops by 1.5 bar
to 8.5 bar over a test period of 2 h.
Result
» After a test period of 2 h, the pressure drop is more than 1.5 bar.
Measure
Renew evaporator.
Slowly unscrew special tool 0 496 223 (64 5 121) for the pressure drop
from special tool after the leakage test.
Loosen screws (1).
Remove special tool .
POSTPROCESSES
3 – Evacuate and fill air conditioning

See additional information.
Overview of Tightening Torques
Overview of Special Tools

0 496 714 (00 9 030) Wedge
Common Used in step 2
Usage For dismantling O-rings, gaskets and trim panels. This

special tool replaces special tool 00 9 316.
Included in the tool
or work
Storage location A50
Replaced by
In connection with
SI-Number 01 20 09 (581)
0 496 223 (64 5 121) Hose

Common Used in step 2
Usage (Connection hose with clamp)
Included in the tool 0 496 222
or work
Storage location Individual
Replaced by
In connection with
SI-Number 01 04 08 (435)
Overview Technical Data
Links
Repair instructions Used in step
64 50 010 Extract, evacuate and fill air conditioning system 13
64 50 010 Drawing off, evacuating and filling air conditioning (R134a) 13
64 50 010 Drawing off, evacuating and filling air conditioning (R134a) 13
64 50 ... Notes on repairs to air conditioning 13
64 50 010 Drawing off, evacuating and filling air conditioning (R1234yf) 13
64 50 ... Safety information for handling refrigerant R1234yf 13
64 50 ... Safety information for handling tetrafluorethane refrigerant R134a 13
64 50 ... Safety informations for handling refrigerant oil 13
64 51 522 Removing and installing or replacing expansion valve
Warning!
Risk of injury!
Follow safety instructions for handling R 134a refrigerant.
Follow safety instructions for handling refrigerant oil.
Important!
Risk of damage!
Restart engine only when A/C system has been correctly filled.
Follow instructions for opening and replacing parts in refrigerant
circuit!
If A/C system is opened for more than 24 hours:
Replacing drier insert for A/C system

Drawing off, evacuating and filling the A/C system are not
included in the time value given for this work operation
Remove heater bulkhead
Unfasten nut.
Installation: Tightening torque 64 53 10AZ.
Release screws.
Detach refrigerant lines in direction of arrow.
Installation:
Replace sealing rings and moisten with refrigerant oil.
If necessary, pull lock (1) in direction of arrow and feed out flap (2).
Slacken nut (1).

Installation:
Detach double pipe (2) in direction of arrow and lay to one side.
Release screws.
Installation:
Pull out expansion valve in direction of arrow.
After installation:
64 51 590 Removing and installing/replacing evaporator
Note: Heater is removed.
Remove heating element.

Remove output stage/switch for blower of heater - A/C.
Withdraw temperature sensor (1).

Unclip linkage (3) on servodrive.
Unlock servodrive (1), remove and disconnect plug connection.

Release screw (2).
Unlock plate (3) (see magnifying glass) and remove.
Installation:
Insert lugs (4) first.
Unclip wiring harness.
Turn cam disk (1) until microswitch (2) can be unclipped and removed.
Release screws on fan housing.
Lift off blower housing (1) and feed out double pipe (2).
Installation:
Unclip retainers (1) and remove lower housing (2).
Remove evaporator (1).Replacement only:

Remove expansion valve (2).
Caution!
Do not bend cooling fins.
If necessary, clean/align cooling fins with slat comb.
circuit
00 9 030
32 1 270
Warning!
Attention!
Procedure:
Evaporator: 10 ml
Capacitor: 20 ml

Procedure:
replaced:
Evaporator: 35 ml
Capacitor: 35 ml
64 52 ... Notes for changing the air conditioning compressor, determining
the amount of refrigerant oil (amount of refrigerant oil of new air conditioning
compressor known)
Note:
This procedure only applies if the new air conditioning compressor has
a label with the amount of refrigerant oil.
A different procedure applies for air conditioning compressors without a
label indicating the amount of refrigerant oil.
Attention!
Risk of damage!
branches.
Attention!
Desiccant insert
Refrigerant oil
BMW i, PHEV: all expansion valves
BMW i, PHEV:
Rinse the refrigerant circuit
All vehicles without I01 with heat pump:
refrigerant oil.
Only I01 with heat pump:

The new air conditioning compressor and new dryer flask are
filled at the factory with refrigerant oil.
compressor and in the new dryer flask corresponds to the
amount of refrigerant oil for the entire new and unfilled refrigerant
circuit.

BMW I01with heat pump: An adaptation is also required for the
replacement of the dryer flask.
An adaptation of the amount of refrigerant oil is not required in
the following cases:
If the refrigerant circuit was rinsed (only BMW i, PHEV).
Step 1:
Determination of the amount of refrigerant oil drawn off from the
refrigerant circuit:
station display.

service station.
The refrigerant oil amount specification is located on the label on
the air conditioning compressor.
The position of the label can vary depending on the air
Information about the amount of refrigerant oil is provided on the
label in g, ml or cc.
Ml are specified throughout these repair instructions for adjusting
the amount of refrigerant oil, as g or cc closely correspond to ml.
Step 2:
Compare information of amount of refrigerant oil of the present and new
air conditioning compressor:
Read and record amount of refrigerant oil specified on the previous
air conditioning compressor.
(If there is no label, continue with Step 3, Case 1 .)
Read and record amount of refrigerant oil specified on the new air
Compare both amounts of refrigerant oil with each other.
Different cases:
1. The information of the amount of refrigerant oil on the present and
new air conditioning compressor is the same. In this case continue
with Step 3, Case 1.
2. The information of the amount of refrigerant oil on the present and
new air conditioning compressor is not the same:
Different cases:
1. Information of the amount of refrigerant oil on the present air
conditioning compressor is higher than the information of the
amount of refrigerant oil on the new air conditioning
compressor:
Difference is not taken into account. In this case continue with
Step 3, Case 1.
2. Information of the amount of refrigerant oil on the present air
conditioning compressor is lower than the information of the
amount of refrigerant oil on the new air conditioning
compressor:
Generate and record the difference between both amounts
of refrigerant oil. After that continue with Step 3, Case 2.
Example:
Information of the amount of refrigerant oil of present air conditioning
compressor 110 g
Information of the amount of refrigerant oil of new air conditioning
compressor 150 g
150 g - 110 g = 40 g correspond to almost 40 ml
Note the difference of 40 ml.
Step 3:
Determination of the amount of refrigerant oil in the new air conditioning
compressor:
compressor.
Different cases:
Case 1:
Add 10 ml precautionary allowance to the read amount of
refrigerant oil.
Note at least but a total of 50 ml.
Example:
compressor = 50 ml
Case 2:
Add the 10 ml precautionary allowance to the read amount of
refrigerant oil.
Add the difference to that.
Note at least but a total of 50 ml.
Example:
Difference = 40 ml
20 ml + 10 ml precautionary allowance = 30 ml
30 ml + 40 ml difference = 70 ml > 50 ml
compressor = 70 ml
Step 4:
Determination of the amount of refrigerant oil to be drained from the new
air conditioning compressor:
Drain the following amount of refrigerant oil from the new air
conditioning compressor into a clean measuring cup:
Amount of refrigerant oil to be drained from the new air conditioning

compressor = amount of refrigerant oil on the label of the new air
conditioning compressor - determined amount of refrigerant oil in the
new air conditioning compressor
Example:
Amount of refrigerant oil stated on the label of the new air conditioning
compressor: 150 ml
determined amount of refrigerant oil of the new air conditioning
compressor: 50 ml
Amount of refrigerant oil to be drained = 150 ml - 50 ml = 100 ml
100 ml must be drained from the new air conditioning compressor.
properly.

Step 5
Fill the refrigerant circuit with the correct amount of refrigerant and
refrigerant oil:
Before filling the air conditioning with refrigerant, again fill in the
quantity of refrigerant oil noted in Step 1 as previously drawn off into
the system.
Fill A/C system.
Step 6
Attention!
Risk of damage!
Note:
system.
Manual:
output.
Body
Step 7
Dispose off the drawn off refrigerant oil:
Installation note:
64 52 ... Notes on changing the air conditioning compressor, determining the
amount of refrigerant oil (amount of refrigerant oil of new air conditioning
compressor not known)
Note:
This procedure only applies if the new air conditioning compressor
does not have a label with the amount of refrigerant oil.
A different procedure applies for air conditioning compressors with a label
indicating the amount of refrigerant oil.
Attention!
Risk of damage!
branches.
Attention!
Desiccant insert
Refrigerant oil

refrigerant oil.

An adjustment of the amount of refrigerant oil is not required in
the following case:
station display.

service station.

compressor.

Fill the entire contents of the new air conditioning compressor in a
clean collecting vessel.
Fill the same quantity of refrigerant oil (from the new air conditioning
compressor), as was drained from the present air conditioning
compressor, + 10 ml precautionary allowance in a clean measuring
cup and again fill it in the new air conditioning compressor . At least
but a total of 50 ml.
Example:
compressor = 50 ml
properly.


Before filling the air conditioning with refrigerant, fill in the noted
quantity of refrigerant oil previously drawn off, into the system.
Fill A/C system.
Attention!
Risk of damage!
Note:
system.
Manual:
output.
Body
Installation note:
64 52 520 Removing and installing/replacing complete A/C compressor (M47,
M47TU)
Caution!
Follow instructions for compressor replacement without fail.
Note:
A/C system is drawn off.
Remove compressor drive belt.
M47:
Remove intake neck.

Unscrew nut (1).
Unhook vacuum hose (2) from mounts (3).
Lever out vacuum tank (4) and place to one side in direction of arrow.
Loosen screws (1).

Remove lines (2) and (3).
Installation:
Disconnect plug connection (4) in direction of arrow.
M47TU:
Remove air funnel.

Unscrew nut (1).
Detach vacuum hose (2) in direction of arrow.
Lift off vacuum tank (3) and place to one side.
Note:
For purposes of clarity, illustration shows removed charge pressure pipe.
Loosen screws (1).

Remove lines (2) and (3).
Installation:
Disconnect plug connection (4) in direction of arrow.

All:
Note:
Secure A/C compressor (2) against falling out.
Release screws (1) and remove A/C compressor (2).

1. Qualification:
controls.
2. Identification:
vehicle!
water foam).
engine is running.
any other work.
and damage.
be replaced.
safety screws.
32 1 270
hours.
E84, E89
circuit
00 9 030
32 1 270
Warning!
Attention!
Procedure:
Evaporator: 10 ml
Capacitor: 20 ml

Procedure:
replaced:
Evaporator: 35 ml
Capacitor: 35 ml
Attention!
Note:
condenser (2-6).

64 51 ... Leak-testing condenser

00 9 030
64 5 121
64 5 122
64 5 123
Warning!
Risk of injury!
Follow safety instructions for handling refrigerant
Comply with the standard national safety instructions and
precautions on handling nitrogen.
vessels and nitrogen correctly (danger of asphyxiation). For this
purpose, follow the notes and instructions in the technical safety
specifications available from the gas supplier.

Detach refrigerant lines from condenser
E70 only:
Important!
Risk of damage!
Special tool 64 5 122 and special tool 64 5 123 have different
diameters (A, B) at the seal plugs!
Ensure correct connection assignment on condenser.
Fit and secure sealing adapter 64 5 123 to connection of low-pressure
line.
Fit and secure test adapter 64 5 122 to connection of high-pressure line.
E70 only:
Important!
Pressurize condenser to 10 bar slowly only. Excessively fast
pressurization and pressures in excess of 20 bar may cause
damage to the condenser.

Note:
Testing apparatus must be leakproof.
during the test procedure.
Check leak-tightness of testing apparatus and of connection to
refrigerant line.
leak in the condenser unit.
Warning!
After leak-testing, unscrew special tool 64 5 121 slowly from
After leak-testing:
Replace sealing rings. Use special tool 00 9 030 to mount sealing
rings without damaging them.
Assemble A/C system
64 53 510 Removing and installing/replacing dryer flask for heating and air
conditioning system
Note:
Heating and air conditioning system has been drawn off.
Comply with notes on dryer flask replacement.
M3 only:
Remove right headlight.
All except for M3:
Remove washer fluid reservoir for window washer system.
All:
Release screws.
Pull pressure and intake pipe upwards.
Note:
Seal pressure and intake pipe with seal plugs if the heating and air
conditioning system remains open for longer than one hour.
Installation note:
Release screws.
Release screws.
Feed out wheel arch cover.
Slacken screws.
Pull out dryer flask towards bottom.
Note:
In event of warranty application, seal pipe aperture with seal plugs of new
dryer flask.
equipment)
Warning!
Important!
direct sunlight.
Important!
Important!
fumes directly.
agent/paint.
cream.
Important!
First Aid:
Recycling:
65 11 070 Removing and installing / replacing CD-changer
Touring:
Remove flap in luggage compartment trim panel on left.
Loosen screws (1).
Withdraw CD changer (2) and disconnect plug connections.
Replacement:
Remove CD changer holder.
Saloon/Sedan and Coupé:

Remove luggage compartment wheel arch trim on left.
Loosen screws (1).
Replacement:
Convertible:
Remove holder for radio receiver.
Loosen screws (1).
Replacement:
65 11 040 Removing and installing/replacing radio control panel (radio
navigation)

refer to 51 16 221.
Release screws and pull out radio control panel.
Disconnect plug.
65 11 030 Removing and installing/replacing radio receiver (built-in unit)

refer to 51 16 221.
Release screws and pull out radio.

65 11 055 Removing and installing/replacing radio receiver (radio navigation
or on-board monitor)
Unlock plug connections (1) and (2) and disconnect.

Release screw (3).
Feed out radio receiver (4) in direction of arrow and remove.
Installation:
Metal tabs (1) of radio receiver (2) must be seated in mountings (3) of
holder (4).
Replacement:
Unscrew nut (1).
Remove holder (2) from radio receiver (3).
65 12 ... Install the correct navigation map (after replacing the head
unit as from 07/2015)
Install the correct navigation map depending on the validity of the customer subscription after having replaced
the head unit for vehicles with a production date as from 07/2015.
Different cases:
Customer subscription is still valid:
Install the most recent navigation map.
Customer subscription has expired:
Check when the customer subscription expired*.
Install the navigation map applicable on the expiry date.
The customer subscription has expired. After the expiry of his/her subscription, the customer purchased a
newer version of the navigation map ("One Time Update"):
Check which navigation map was installed most recently*.
Install this navigation map
* The information required to determine the term of the customer subscription is available in the following path:
Aftersales Information Research (AIR)
Navigation map
The following table is displayed in the "Navigation map" menu:
Installed map Enabling code Free update Update subject to a charge

(Status with date) (Subscription)
In this field the Displayed in this Displayed in this field is: Displayed in this field is:
currently installed field is:
map with year During a valid The field is empty during a
specification is Validity of subscription of the valid subscription
displayed. the current, free enabling The next available, most
subscription code recent enabling code subject
(E.g. navigation map (E.g. valid The last functional, free to a charge if the subscription
Europe 2015) until enabling code is shown if or "one time update" has
31.10.2017) the subscription or "One expired
or an time update" has expired
enabling
code for
"One Time
Update"
Go to the following path for more information on navigation, such as update variants, new features and
compatibility tables:
After-sales Assistance Portal (ASAP)
Product information bulletin
07 Infotainment and communication
03 Navigation update
65 12 070 Removing and installing / replacing amplifier

Remove parcel shelf in luggage compartment on left.

Loosen screws (2).
Remove amplifier (3) with holder.
Replacement:
Loosen screws (1).
Remove holder (2) from amplifier (3) towards top.
65 12 020 Removing and installing/replacing rear speaker
Unclip speaker frame (1).
Release screws (1), lift speaker (2). Remove speaker dish (4) and
disconnect plug connection.Installation:
Ensure speaker dish (4) and cable (3) are correctly seated.
65 12 000 Removing and installing/replacing speaker (front left or right door)
Remove and install/replace speaker.
65 12 000 Removing and installing/replacing speaker (front left or right door)
Remove and install/replace speaker.
65 13 050 Removing and installing/replacing speaker (treble speaker in
quarterlight mirror)
Remove front door trim panel.

Saloon/sedan, touring only:
Detach cover on door frame in front area.
Compact only:
Release expansion rivet (1).
Detach cover on door frame (2) in direction of arrow and lever out of
retainers (3) towards rear.
All:
Note:
For purposes of clarity, cover on door frame is removed.
Remove foam wedge (1) in direction of arrow from door frame (2).
Fold down sound insulation on front door (1) in direction of arrow.

Disconnect plug connection underneath for speaker cable (2).
Installation:
Fit sound insulation on front door.
Release screw (1) and remove mounting (2).
Feed speaker (3) in direction of arrow out of screw (4) and remove.
61 13 ... Antenna elbow plug on radio receiver
Important!
This repair solution is only possible
up to model year 10/ 2000.
Replace entire antenna cable on affected vehicles.
Refer to Spare Parts Catalogue.
Cut off faulty antenna angle plug directly after strain relief.
Carefully and with precision, strip insulation from antenna cable as
illustrated (lengths given in mm).
Brush shield (copper braid) towards rear.
Important!
There must be no more copper wire protruding in the direction of the
inner conductor on the inner conductor insulation (risk of short
circuits).
Create a loop on inner conductor.
Important!
Cover soldering area extensively in center console all round radio
aperture.
Avoid blobs of melted solder in inside area.
Tin-plate center connection on antenna angle plug and stripped inner

conductor.
Solder inner conductor on center connection with a small soldering iron
(max. 50 watts) and matching soldering tip (1).
Gently push insulation forward to soldering point and pay attention to
correct position of loop.
Note:
The loop must not under any circumstances come into contact with the
metal parts of the antenna plug.
Special tool 61 9 041 (hand pliers) in conjunction with special tool
61 9 044 (matrix) is used to crimp antenna angle plug.Refer to repair
instructions:
Unlock special tool 61 9 041:

Squeeze grips (1) lightly and push unlocking lever (2) in direction of
arrow.
OR:
Compress handles as far as they will go, tool unlocks automatically.
Place antenna angle plug with cable guide and strain relief in matrix (1).
Compress special tool 61 9 041 as far as it will go.

Special tool 61 9 041 unlocks automatically.
Remove antenna angle plug with antenna cable from special tool
61 9 044.
61 35 900 Removing and installing/replacing ring antenna of electronic
immobilizer

61 3 300

E46 only: Remove lower section of steering column trim
Slide in special tool 61 3 300 with flattened end (A) facing ring antenna
and lever out ring antenna.
65 24 010 Removing and installing or replacing antenna amplifier
Remove panel for rear left roof pillar (C-pillar),

refer to 51 43 251.
Unfasten plug connection (1). Disconnect antenna cable (4). Release

screws (2) and remove antenna amplifier (3).
65 24 020 Removing and installing or replacing block circuit
Remove panel for rear right roof pillar (C-pillar),

refer to 51 43 251.
Unfasten plug connection (1). Release screw (2) and remove block
circuit (3).
65 50 010 Removing and installing/replacing video module for on-board
monitor
Mark antenna plugs (1) and disconnect.

Release screw (3).
Feed out video module for on-board monitor (4) in direction of arrow and
remove.
65 50 020 Replacing video module for on-board monitor and loading
operating software
Remove and install/replace video module for on-board monitor.
Installation:
Load operating software.
65 52 013 Removing and installing complete on-board monitor (widescreen)

65 1 110
Remove center fresh air grill (with decorative strip).
Note:
Use of special tool 65 1 110 , shown on left side with complete on-board
monitor removed (same procedure applies for use on right side):
Feed in special tool 65 1 110 for extended trim for on-board monitor (3)
as illustrated until pawl (1) of catch (2) snaps into place.
After removing complete on-board monitor, press catch (2) and feed out
special tool 65 1 110 again.
Extend trim for on-board monitor (1) as illustrated.

Note:
Trim for on-board monitor (1) returns after approx. 15 seconds to its initial
position.
Using special tool 65 1 110 , unlock complete on-board monitor (2) at

bottom left and right and pull out in direction of arrow.
Note:
Secure complete on-board monitor (2) against falling out.
Unlock side plug connections and disconnect.

Remove complete on-board monitor (2).
Installation:
When sliding in complete on-board monitor (1), make sure catches (2) on
both sides are correctly seated.
65 52 010 Removing and installing on-board monitor
Remove center fresh air grill (with decorative strip).
Pull off moulded menu button (1) in direction of arrow.
Insert screwdriver (1) in opening (3) of lock (4).
Using screwdriver (1), turn lock (2) as far as it will go in direction of arrow
and pull out complete on-board monitor (3) on left towards rear.
Then, using screwdriver (1), turn lock (2) as far as it will go to left and pull
out complete on-board monitor (3) on right towards rear.
Disconnect plug connections (1) and (2) and remove complete on-board
monitor.
65 52 040 Removing and installing/replacing complete housing with drive for
on-board monitor
Remove and install trim panel for on-board monitor,

refer to 65 52 020.
65 52 043 Removing and installing/replacing housing with drive for on-board
monitor (widescreen)
Remove panel for on-board monitor (control panel, widescreen).Note:

After removing panel for on-board monitor, reconnect housing with drive
for on-board monitor to power supply until retaining brackets for monitor
panel are fully retracted.
65 52 030 Removing and installing/replacing LC display for on-board monitor
Remove and install/replace trim panel for on-board monitor,

refer to 65 52 020.
65 52 023 Replacing panel for on-board monitor (control panel, widescreen)
Important!

Remove complete on-board monitor (widescreen)
Note:
When removing complete on-board monitor (widescreen), disconnect
plug connections with trim for on-board monitor extended.
Remove bolts (1) and (2).

Remove upper housing (3) in direction of arrow from housing (4).
Remove bolts (1) and (2).

Lift out cassette deck (3) and place to one side.
Note:
Cassette deck (3) is still connected to housing by ribbon cable for
cassette deck (4).
Open catches (1) in direction of arrow.

Feed ribbon cable for cassette deck (3) in direction of arrow from contact
terminal (2).
Installation:
Make sure ribbon cable for cassette deck (3) is correctly seated in
contact terminal (2).
Lever out expansion rivet (1).
Open catches (2) and (3) in direction of arrow.
Feed ribbon cables (4) resting on top of each other out of contact
terminals.
Installation:
Make sure ribbon cables (4) are correctly seated in associated contact
terminals.
Release screws (1).
Note:
Carefully feed out ribbon cables (3) when removing trim for on-board
monitor (1).
Remove trim for on-board monitor (1) in direction of arrow from

housing (2).
65 52 020 Replacing trim panel for on-board monitor (control panel)
Remove and install complete on-board monitor,

refer to 65 52 010.
Caution!
Place trim panel on special tool 12 7 192 (anti-static mat) and
ground.
Release screws (1) and tilt trim panel out from above.
Release screws (1) and remove LC display.
Installation:
Lay wire (1) downwards.
65 75 551 Removing and installing/replacing pitch sensor
touring only:
Remove rear speaker on right.
Pull out cable guide (1).

Remove expansion rivet and release nuts (2).
Lift off resonance body (1) slightly.

Detach relay receptacle (2).
Disconnect plug connection (3), unclip tilt sensor (4) and remove.
Saloon/sedan, coupé, convertible:

Release right trunk wheel arch trim in rear area.
Note:
Secure nuts (1) against falling out.
Unscrew nuts (1).

Remove holder for tilt alarm sensor (2) towards inside.
Disconnect plug.
Replacement:
Unclip tilt sensor from holder.
65 75 565 Removing and installing/replacing ultrasound module
Remove trim (1) and disconnect plug connection.
Replacement:
Lever out retaining clips (1) and remove ultrasound module (2).
(central airbag control unit, airbag system)
The gas generator is a pyrotechnic component of:
Airbag module
Side airbags
Head airbag
Knee airbag
Seat belt tensioner
Battery safety terminal
1 Series: E81, E82, E87, E88
3 Series: E46, E90, E91, E92, E93
X3:E83
X5: E53, E70
Z4: E85, E86
For vehicles mentioned above that are scheduled for scrapping, it is always essential prior to draining and
further disassembly work to ensure that all the gas generators in the vehicle are fired. The fired gas
generators can then be scrapped together with the vehicle.
Firing failure
If correct triggering is not possible, the relevant components must (while observing the safety regulations for
approach the vehicle only after a few minutes
on as used parts.
Ignition
also be observed.
developed triggering device with the corresponding cables.
Warning!
The burning of solid fuel will heat up airbag unit - danger of burning hands!
1. Vehicles with central airbag control unit (all airbags, seat belt tensioners, battery safety terminal)
1.1 Expose airbag control unit.

1.2 Connect ”Airbagmaster”. For subsequent procedure, refer to SEDA operating instructions.
65 77 016 Removing and installing airbag control unit
Warning!
Note airbag safety instructions!
Incorrect handling can activate airbag and cause injury.

Remove storage compartment
Cut carpet (1) along premarked line and fold back.Installation:

Secure carpet (1) to position (2) using cable strap.
Release nuts (2), tightening torque 65 77 1AZ.

Raise airbag control unit.
Installation:
Before installing airbag control unit, make sure earth/ground cable is
resting on stud bolt (1).

Lift out airbag control unit.
65 77 551 Removing and installing impact sensor for left or right side airbag
(multiple restraint system 4)
Warning!
Turn ignition key to 0 position.

Remove front seat.
Remove entrance cover strip.
Saloon/Sedan, Touring:
Fold up carpet in area of front seat. If necessary, remove rear
compartment heating duct.
Disconnect plug.
Release screws and remove impact sensor for side airbag.Installation:

Arrow (1) on impact sensor for side airbag must point to sill.
Coupé, convertible, compact:
Remove cable strap (1).
Unscrew clip (2).
Fold up carpet in area of front seat.

Release screws (2) and remove impact sensor for side airbag.
Installation:
65 77 550 Removing and installing/replacing impact sensor for left or right
side airbag
Warning!
Turn ignition key to 0 position.

Remove front seat.
Remove entrance cover strip.
Saloon/Sedan, Touring:
Fold up carpet in area of front seat. If necessary, remove rear
compartment heating duct.
Disconnect plug.
Release screws and remove impact sensor for side airbag.Installation:

Coupé, convertible, compact:
Remove cable strap (1).
Unscrew clip (2).
Fold up carpet in area of front seat.

Release screws (2) and remove impact sensor for side airbag.
Installation:
65 77 518 Replacing airbag control unit

Remove airbag control unit
Installation:
65 77 552 Replacing impact sensor for left or right side airbag (multiple
restraint system 4)
Remove impact sensor for side airbag.
Installation:
Code airbag control unit.
65 77 600 Replacing sensor mat for passenger seat occupancy detector

”Replacing seat cover for left or right front seat”.
65 81 060 Removing and installing/replacing external temperature sensor

64 1 020
Expand mount for outside temperature sensor with special tool 64 1 020
and feed out outside temperature sensor (1) in direction of arrow.
Pull out ambient temperature sensor (1).
Disconnect plug connection and remove ambient temperature
sensor (1).
Installation:
Make sure ambient temperature sensor (1) engages correctly in its
mount.
65 90 ... Notes on handling navigation computers
Important!
Risk of damage!
The navigation computer must not be cut off from the voltage
supply for as long as the LED on the computer remains on. (the LED
goes out after approx. 1 minute).
Software installation:
The navigation software must be loaded with terminal 15 activated and
the navigation system ready for operation.
Make sure in so doing that the voltage supply is stable. If necessary,
connect a battery charger to the vehicle.
The charging procedure must not be interrupted (terminal 15 remains
activated).
The software is loaded when the operating software CD is ejected.
Note:
To ensure full operation of all the communications components, it is
necessary in new cars to insert a Road Map CD (DVD) in the navigation
computer.
This is absolutely essential as certain functions are disabled for
distribution channels.
These functions will only be available again after a Road Map CD (DVD)
has been inserted. The mode preset at the factory is automatically reset
when this CD (DVD) is inserted.

Carry out vehicle programming/encoding.
Only E46 and E83 with radio navigation system (SA606):
Connect diagnosis system to vehicle.
procedure)
Start session
Selection via path:
Vehicle
Change language - Set navigation to corresponding language
Create action plan
Accept action plan
Upon request from the diagnosis system, insert the current
BMW navigation system CD into the navigation system drive.
until this happens)
Follow the instructions on the radio navigation system display
Carry out vehicle programming/encoding
To update the navigation software:

procedure)
Insert the current BMW navigation system CD into the navigation
system drive
until this happens)
65 90 510 Removing and installing/replacing navigation computer with CD-
drive

65 5 400
Note:
Japanese national variant only:
When the navigation computer is being pulled out, the computer's
connectors may touch the computer holder.
If necessary, remove navigation computer holder and unlock and
disconnect plug connections on navigation computer.
Touring:
Remove flap in luggage compartment trim panel on left.
Release navigation computer (1) with special tool 65 5 400 (2) and pull
out.
Unlock plug connections behind and disconnect.
Saloon, Coupé:
out.
Convertible:
out.
compact:
Remove flap in luggage compartment panel on left.
out.
Replacement:
Observe instruction for Replacing codable/programmable control units.
65 90 550 Replacing CD/DVD drive for navigation computer

00 9 318
Important!
damage (ESD protection)!
Comply with notes and instructions on handling navigation computers.

Replace the destroyed seal on all devices with the new seal supplied.

Remove navigation computer
MK II version:
Cut through seal (1).
Release screws (2) on both sides and carefully fold down front panel (3).
Installation:
Replace the destroyed seal with the new seal supplied.
Lever cover (1) with special tool 00 9 318 upwards out of side catches.
Release screws (1) and carefully lift out CD drive (2).
MK III and MK IV versions:

Cut through seal (1).
Carefully lever off cover (2) with special tool 00 9 318 .
Installation:
Replace the destroyed seal with the new seal supplied.
MK III version:
Release screws (1) and carefully lift out drive (2).
Important!
Ribbon cables and connectors must not be damaged!
Disconnect plug connections (1) and remove drive (2).

MK IV version:
Release screws (1).
Carefully lift out DVD drive (2).
Important!
Ribbon cables and connectors must not be damaged!
Disconnect plug connections (1) and remove DVD drive (2).

66 20 540 Removing and installing/replacing a rear ultrasonic transducer
(Park Distance Control)
Remove and install/replace ultrasonic transducer (Park Distance Control).
66 20 510 Removing and installing/replacing control unit (Park Distance
Control)
Saloon/Sedan, Coupé:
Detach left trunk wheel arch trim in rear area.

Slacken screws (2).
Feed holder for control unit (4) in direction of arrow out of elongated
holes (3) and remove.
Replacement only:
Unscrew nuts (1).
Remove control unit (2) from control unit holder (3).
Convertible:
Remove lower section of side trim at rear right.
Release screws (1) and remove control unit holder (2).

Disconnect plug connections (4). Replacement only:
Unscrew nut (1).
Pull control unit (2) in direction of arrow out of guide (3) and remove.
Installation:
Pay attention to cable guide.
touring:
Slacken panel for trunk floor plate at front.
Note:
For purposes of clarity: Illustration shows trunk floor removed.
Loosen nut (1). Unscrew nut (2).

Raise control unit and remove.
compact:
Remove side panel cover.

Unscrew nuts (2).
Lift out control unit (3).
67 11 555 Removing and installing/replacing servodrive for tank filler flap
Saloon/Sedan, Coupé:
Remove right luggage compartment wheel arch trim in rear area.

Slacken screws (2).
Feed out servodrive for tank filler flap (3) towards rear and pull in direction
of arrow out of gaiter (4).
touring:
Remove flap in right luggage compartment wheel arch trim.
Unhook pull strap for emergency actuator (1) in direction of arrow from
guide (2).
Remove fluid reservoir for rear window washer system and place to one
side.

Slacken screws (2).
Feed out servodrive for tank filler flap (3) towards rear and pull in direction
of arrow out of gaiter (4).
compact:
Disconnect emergency actuator for tank cap.
Fold down sound insulation.
Slacken screws (2).
Feed out servodrive for tank filler flap (3) towards rear and pull out in
direction of arrow.
Convertible:
Removing right luggage compartment wheel arch trim.

Slacken screws (2).
Feed out servodrive for tank filler flap (3) towards rear and pull out in
direction of arrow.
All:
Installation:
Insert servodrive for tank filler flap (1) in direction of arrow into gaiter (2).
Replacement:
Remove pull strap for emergency actuator (1) in direction of arrow from
servodrive for tank filler flap (2).
67 11 560 Replacing actuator drive for rear lid locking

”Removing rear lid lock”
67 13 001 Replacing drive unit for electrically operated left or right door
mirror

Remove mirror glass for mirror
Release screws (1).

Fold out drive unit for electrically operated door mirror (2) in direction of
arrow.
Disconnect plug connection (1) and remove drive unit for electrically
operated door mirror (2).Important!
In order to avoid ingress of water in non-sealed plug housing, coat
plug housing (1) at cable and connection ends with battery terminal
grease.
67 13 005 Replacing drive unit for electrically operated left or right door
mirror (with memory)

Remove mirror glass
Release screws (1).

Release drive unit for electrically operated door mirror (2) in direction of
arrow and expose wiring harness underneath.
Disconnect wiring harness (1) as illustrated and remove drive unit for
electrically operated door mirror (2).Installation:
Wiring is carried out with connectors.
Secure wiring harness (1) against flapping/rattling.

64 1 020
Warning!
Caution!

All models except US:
Remove sidelamp bulb holder from headlight.
Disconnect plug connections for low and high beams.

Turn retaining rings and remove both bulb holders.
Remove cover frame towards front from headlight.

Note:
Detach covers for low and high beams.Installation:

Make sure covers are correctly seated.

All:
Press headlight insert at an angle towards front/bottom until inner
headlight vertical aim adjuster snaps audibly out of its guide.
Turn thumbwheel (1) clockwise until internal adjusting element is free
(headlight insert can then be tilted out towards front!).
Installation:
Make sure adjusting element is correctly seated in guide.
Make sure headlight insert at bottom is correctly seated on ball socket of
internal headlight vertical aim adjuster.

Tilt headlight insert (2) in direction of arrow out of headlight housing (1)
and feed out of ball socket (3).
Installation:
Make sure headlight insert (2) is correctly seated on ball socket (3) of
headlight housing (1).
All others:
Feed headlight insert (1) out of guide and remove towards

front.Installation:
Make sure headlight insert (1) is correctly seated in guide.
Note:
Installation:
Insert guide (1) on headlight insert into rail (2).
Unclip inner plug (1) with special tool 64 1 020 in direction of arrow.
Pull out plug (1) in direction of arrow.

Release screws (2) and remove headlight vertical aim adjuster (3) in
direction of arrow.
Installation:
Make sure cable (4) is correctly seated in guides (5).
All others:
Note:
Disconnect plug.
All:
Installation:
Adjust headlights.
Warning!
Caution!

Remove lamp for xenon light.
Remove halogen bulb for high-beam headlight.
Remove cover frame (1) in direction of arrow from headlight housing (2).
Turn sidelamp bulb holder (2) in direction of arrow and remove.

Remove high beam cover (1) in direction of arrow.
Installation:
Make sure high beam cover is correctly seated.
All models except M3:
To install cover for high beam, if necessary release control unit holder for
xenon headlight.
All:
Press headlight insert (1) at an angle towards front/bottom until inner

headlight vertical aim adjuster (2) snaps audibly out of its guide (3).
Turn thumbwheel (1) clockwise until headlight insert (2) is free.

Tilt out headlight insert (2) in direction of arrow and feed out of guide (3).
Remove headlight insert (2).
Installation:
Make sure headlight insert is correctly seated in guide (3).
Then clip headlight insert (2) onto ball socket of inner headlight vertical
aim adjuster.
Installation:
Insert guide (1) on headlight insert into rail (2) of headlight housing.
If necessary, make sure pin (3) of adjusting lever for right/left-hand traffic
is correctly seated in bore (4).
Disconnect plug.
Installation:
Adjust headlights.
Remove right headlight (xenon headlight).
67 31 531 Removing and installing/replacing drive for backrest angle
adjustment (front seat removed)
Saloon/sedan, coupé, touring:

Note:
Secure drive for backrest angle adjustment (5) against falling out.
Release screws (3).

Remove drive for backrest angle adjustment (5) with fixture for plug
connection (2) in direction of arrow from flange (4).
If necessary, remove inner drive shaft from drive for backrest angle
adjustment (5).
Installation:
Make sure drive shaft (1) is correctly seated.
Ensure fixture for plug connection (3) and drive for backrest angle
adjustment (4) on flange (2) are correctly seated.
Convertible:
Unhook backrest cover (1) from backrest frame (2) as illustrated and fold
over.
Turn plug connection (1) in direction of arrow and unclip from backrest
frame (2).
Note:
Secure drive for backrest angle adjustment (2) against falling out.
Release screws (1) and remove drive for backrest angle adjustment (2)
in direction of arrow.
If necessary, remove inner drive shaft from drive for backrest angle
adjustment (2).
Installation:
Ensure drive for backrest angle adjustment (2) is correctly seated on
inner flange.
Installation:
Ensure drive shaft (1) is correctly seated in drive for backrest angle
adjustment (2).
67 31 501 Removing and installing/replacing drive for longitudinal seat

Unclip plug housing (2) in direction of arrow from retaining fixture
underneath.
Note:
Secure drive for longitudinal seat adjustment (4) against falling out.
Release screws (3) and remove drive for longitudinal seat

adjustment (4) in direction of arrow from flange (5).
If necessary, remove inner drive shaft from drive for longitudinal seat
adjustment (4).
Installation:
Make sure drive for longitudinal seat adjustment (2) is correctly seated
on flange (3).
67 31 521 Removing and installing/replacing drive for seat height
Saloon/sedan, coupé, touring:

Note:
Secure drive for seat height adjustment (3) against falling out.
Loosen screws (1).

Remove drive for seat height adjustment (3) with fixture for plug
If necessary, remove inner drive shaft from drive for seat height
adjustment (3).
Installation:
Ensure fixture for plug connection (2) and drive for seat height
Convertible:
Note:
Secure drive for seat height adjustment (4) against falling out.
Release screws (3).

Remove drive for seat height adjustment (4) with fixture for plug
If necessary, remove inner drive shaft from drive for seat height
adjustment (4).
Installation:
Ensure fixture for plug connection (2) and drive for seat height
67 31 511 Removing and installing/replacing drive for seat tilt adjustment
(front seat removed)

Note:
Secure drive for seat tilt adjustment (5) against falling out.
Loosen screws (1).

Remove drive for seat tilt adjustment (5) with fixture for plug connection
(3) in direction of arrow from flange (2).
If necessary, remove inner drive shaft from drive for seat tilt
adjustment (5).
Installation:
Ensure fixture for plug connection (3) and drive for seat tilt adjustment (4)
on flange (2) are correctly seated.
67 61 510 Removing and installing or replacing drive with gear for actuating
slide/tilt sunroof

Remove ceiling light
Remove panel and disconnect plug connection.
Note:
Secure drive with gear for actuating slide/tilt sunroof (2) against falling
out.
Release screws (1), tightening torque 54 13 1AZ.

Note:
Screws (1) are microencapsulated.
Lower drive with gear for actuating slide/tilt sunroof (2).

Unlock plug connection (3), disconnect and remove drive with gear for
actuating slide/tilt sunroof (2).
Installation:
Insert gear wheel (1) of drive with gear for actuating slide/tilt sunroof (2) in
gear teeth.
E38 from 9/98 for replacement only:

Important!
There is a risk of permanent battery discharge if
programming/coding is not carried out!
Note:
After installing/coding drive for actuating slide/tilt sunroof:
Initialise slide/tilt sunroof.
67 62 000 Removing and installing / replacing flat motor for front left or right
power window unit

00 9 317

Remove front door trim
Note:
To remove the flat motor, it is necessary to detach the acoustic
insulation in the lower area only.
Lever out sealing bead (1) of acoustic insulation (2) with special
tool 00 9 317 .Note:
Work with particular care in area (A) otherwise acoustic
insulation (2) will tear and must be replaced.

Release screws (2).
Installation:
Turn flat motor slightly and lift out in direction of arrow.Note:

Make sure door window glass has not been fully moved downwards.
Convertible from 09/2003:
Replacement:
A normalization must be carried out in order to activate anti-trapping
protection.
Operating sequence for normalization:
Open corresponding window completely.
Press corresponding power window switch into ”Close one-touch
operation” (second switch stage).
Once the upper end position has been reached, hold power window
switch down for approx. 1 second more.
Normalization is thus completed.
Note:
67 65 511 Removing and installing or replacing drive for sun roller blind
Panel for rear parcel shelf removed,

refer to 51 46 000.
Caution!
Do not power up the drive mechanism if it is not completely
connected to the system.
The linkage is subjected to spring pressure if the roller sun blind is
not fully rolled up.
In this case, maintain roller sun blind under pretension and carefully lever
out linkage. Now allow roller sun blind to roll up slowly.
Unclip retaining clips (1) in direction of arrow and lever out linkage on left
and right.
Unclip cable (2). Release screws (1) and remove drive.Installation

instructions:
Attach screws (1) loosely only. Attach linkage and tighten down
screws (1).
67 66 013 Removing and installing / replacing drive unit for lumbar support
on left or right front seat (sports seat)

Detach transparent hose (2) from valve housing (3).
Note:
If necessary, gently heat transparent hose (2) if firmly seated.
If necessary, detach fabric adhesive tape (4).
Detach drive unit for lumbar support (5) with jacket towards rear.
Installation:
Clean adhesive area (1) on backrest frame (2).
Installation:
Transparent hose (1) of drive unit for lumbar support must not be kinked.
Pull off protective film (3) from jacket (2). Stick drive unit for lumbar
support to backrest frame.
If necessary, secure jacket (2) with cable strap.
67 66 010 Removing and installing/replacing lumbar support drive
mechanism on front seat, left or right

E53 comfort seat:
Remove rear panel at bottom
Detach backrest cover (1) in direction of arrow from backrest frame (2).

Detach transparent hose (2) from valve housing (3).
Note:
If necessary, gently heat transparent hose (2) if firmly seated.
If necessary, detach fabric adhesive tape (4).
Detach drive unit for lumbar support (5) with jacket in direction of arrow.
Installation:
Clean adhesive area (1) on backrest frame (2).
Installation:
Transparent hose (1) of drive unit for lumbar support must not be kinked.
Pull off protective film (3) from jacket (2). Stick drive unit for lumbar
support to backrest frame.
If necessary, secure jacket (2) with cable strap.
are being used.


is reached.

cleaner R1.

Components
Procedure
components.
Read fault memory
Rectify faults
Delete fault memory
Delete fault memory
Seat belt system
Components
Automatic reel
Seat belt tensioner
Seat belt buckle
Procedure
Seats
Components
Seat
Airbag module
Procedure
Driver's airbag
Components
Airbag module
Steering Wheel
Procedure
Components
Airbag module
Procedure
Components
Airbag module
Door trim panel
Door in white
Seat
Procedure
Head airbag
Components
Airbag module
A-pillar trim panel
Roofliner
Procedure
Knee airbag
Components
Procedure
Components
Procedure

2 348 128
72 1 210
Important!
Instrument panel
Entrance area


Installation note:
Note:


Note:
points.
Note:

of collecting tray.
Note:
operations.

Warning!

72 00 ... Replacing the seat belt clip

00 5 040
Note:
If the position of the seat belt clip (1) cannot be identified, the position of
the seat belt clip on the opposite side of the vehicle is used.
Insert the seat belt clip (1) in the previous position on the seat belt (2).
Mount the counterpiece (1).

Press the seat belt clip with special tool 00 5 040 .
Check that the seat belt clip and counterpiece (1) are firmly seated.
Note:
If the seat belt clip is pressed too firmly, the counterpiece may
loosen (1).
72 Safety precautions and general information
Notes on safety ‐‐ Safety regulations for handling airbag modules, airbag components and
> pyrotechnical seat belt tensioners
‐‐ Notes on scrapping vehicles with gas generators

>
‐‐ Deactivation/activation pyrotechnical components

>
Handling electrical system ‐‐ Unlocking/locking airbag plug connections

and electronics >
‐‐ Repairing airbag lines
>
‐‐ Handling optical fibres

>
Check ‐‐ Check seat belt

>
‐‐ Checklist for seat belt

>
Airbag system ‐‐ Functional description and checking, refer to Diagnosis system

>
‐‐ Deactivating airbags
>
‐‐ Procedure after airbag deployment.

>
Active pedestrian protection ‐‐ Procedure after actuator triggering

AFGS >
72 12 ... Safety regulations for handling airbag modules, airbag
components and pyrotechnical seat belt tensioners
refer to 32 34 ...
physical injury!
Head airbag (ITS)
law of 13/09/1976).
regulations.
Service.
waiting period:
Danger of injury!
Disconnect battery
2. Transport
3. Storage
regulations.
generators
Important!

Head airbag
1. Regulations
Service.
BMW ISTA.
Disconnect battery
3. Transport
4. Storage
regulations.
72 11 ... Check list for automatic seat belt
Was the automatic seat belt with lower strap replaced after an accident, No Replace complete
e.g. frontal and/or oblique collision in which the impact automatic seat belt
absorbers/deformation elements were permanently deformed?
The following must
(only while seat belt was fastened) also be checked and
replaced, if necessary:
seatbelt mounts on the
vehicle body
seatbelt mounts on the
seat
seat rails.
Yes
Does seat belt lock when pulled out suddenly? No Replace automatic seat
belt (upper seat belt).
Yes
Does the automatic reel eliminate the belt slack? No Replace automatic seat
Yes
Can the seat belt strap be pulled out without jamming? No Automatic reel is loose -
tighten reel.
If fault persists:
Return spring broken -
replace automatic seat
Yes
Does the strap on the front seat belts retract automatically? No Automatic reel is loose -
tighten reel.
Does the strap on the rear seat belts retract automatically,
Excessive friction in belt
a small remaining loop is acceptable guides - replace
automatic seat belt
if this remaining loop is fully retracted when the seat belt strap is readjusted. (upper strap).
Yes
Does automatic reel make a squeaking noise when belt is fastened or Yes Excessive friction in belt
unfastened? guides - replace
automatic seat belt
(upper strap).
Automatic reel is loose -
tighten reel.
No
Is the plastic casing on the belt tongue free from No Replace complete automatic seat belt
damage in the area of the belt opening?
Yes
Is the fully extended seat belt strap free from No Replace complete automatic seat belt
pinches,
burn marks,
tears and cuts,
creasing and
unravelling?
Yes
When the seat belt is fastened, is the belt tongue No Replace complete automatic seat belt
ejected by spring pressure from the buckle when
the ”red button” is pressed?
Yes
Does fastened seat belt lock during emergency No Replace complete automatic seat belt
braking on a dry roadway at double walking
speed?
Yes
Is fully pulled-out seat belt strap free of serious dirt No If dirt and marks cannot be removed with
and other marks? commercially available mild detergent, the automatic
seat belt (upper seat belt) must be replaced.
Yes
In the case of seat-integrated seat belts, is front No Replace both damaged parts and complete
tongue of reclining mechanism or seat rail free of automatic-reel seat belt.
deformation?
The following must also be checked and replaced, if
necessary:
seatbelt mounts on the vehicle body
seatbelt mounts on the seat
seat rails.
Yes
The automatic seat belt is OK!
72 11 ... Checking automatic seat belt
General considerations when checking seat belts:
The seat belts must be checked after an accident.
For the check, you should start by trying to get information on which seats in the vehicle involved in the
accident were occupied. If this is not possible, check all the seat belts in the vehicle and replace them if
necessary.
In the event of deformations on the vehicle, you must subject the components of the restraint system
affected in this area such as e.g.
Seat belt
Triggering sensors
etc.
to a function check and a visual inspection.
If you are in any doubt as to the unimpaired operability of restraint system components, these
components must be replaced in the interests of safety!
If a seat belt has to be replaced following an accident (e.g. in the event of a frontal and/or oblique collision with
permanently deformed impact absorbers/deformation elements or cross-members), the complete seat belt
must be replaced! The complete seat belt comprises:
Upper seat belt
Lower strap
Seat belt buckle (buckle tensioner)
Mounting bolts of all components
The following must also be checked and if necessary replaced:
Seatbelt mounts on the seat
seat rails.
Seat structure (frame, etc.)
Alignment tests on the seat and the seat rails are not permitted!
The following explanations and the checklist for the automatic seat belt can provide help.
An unusable seat belt or a seat belt worn in a serious accident should be destroyed immediately after removal
to guarantee that it can not be used again.
Checking automatic reel and seat belt strap:
The automatic reel has two independent activation systems for seat-belt locking.
The first activation system locks the automatic reel when driving quickly around curves, driving in tight curves,
on extreme inclinations (vehicle rolls over) and during sharp braking or crash.
To check, the seat backrest must be placed in the upright position and both hands held in a supporting position
close to the steering wheel. The brakes are then operated with full intensity while driving on a dry roadway and
at double walking speed.
The seat belt must lock.
The second activation system provides additional safety and is controlled by inertia mass.
If the reel locks when the seat belt strap is pulled out suddenly, this system is also OK.
In addition, the automatic electric reel (EMA) must eliminate belt slack.
Check whether an attempt was made to eliminate belt slack:
Enter, close doors and latch seat belt buckle contact, left
EMA eliminates belt slack
If belt slack was not eliminated, the procedure described below must be followed:
Allow vehicle to assume complete sleep mode and repeat the functional check.
All doors must be closed!
EMA, left, must be installed and connected correctly.
Work through all fault entries before the functional check is carried out again.
Replace defective or actuated automatic electric reels.
Automatic reel does not require servicing and must not be opened.
Precondition for complete, problem-free retraction of seat belt straps:
The seat belt straps must not be twisted!
The seat belt straps must not be damaged!
When placed to one side, the seat belt straps of the front seats must retract fully.
With the seat belt straps in the rear seat bench, a small remaining loop is acceptable due to increased friction
between the strap and the rear seat bench cover if:
this remaining loop is fully retracted when the seat belt strap is reguided.
Seat belt strap should only be cleaned with a lukewarm soap solution or a commercial mild detergent.
Seat belt strap must never be cleaned chemically or dyed.
The automatic reel and seat belt strap must be replaced in the event of:
1. creasing
2. unravelling
3. pinches
4. cracks and tears
5. traces of melting
6. traces of wear on coating of buckle tongue or on seat belt guide loop.
Checking lower strap (belt buckle tensioner):
To fasten a seat belt, the buckle tongue should insert easily and with a loud click in the lock.
When the ”Red button” is pressed, the buckle tongue must be ejected from the lock under spring pressure.
If the seat belt buckle cover is missing or damaged, the lower strap must be replaced.
Replace the triggered belt buckle tensioner including the complete seat belt with seat belt height adjustment
and mounting bolts and check the
seat rails.
Seat structure
Criteria for a triggered mechanical belt buckle tensioner:
very low position of seat belt buckle (comparisons with new part).
Criteria for a triggered pyrotechnical belt buckle tensioner:
very low position of seat belt buckle (comparisons with new part).
Airbag indicator light permanently lit: read out airbag system fault memory.
The belt buckle tensioners can be triggered under certain circumstances even when the seat is not occupied.
If it is definite that the seat belt system was not used (seat was not occupied), there is no need to replace the
Upper seat belt
Add-on parts (seat belt height adjustment, screws)
seat rails.
after a check.
Checking end fitting pretensioner:
Replace the triggered end fitting pretensioner including the complete seat belt with seat belt height
adjustment, lower strap and mounting bolts and check the
seat rails.
Seat structure
Criteria for a triggered end fitting pretensioner:
A triggered end fitting pretensioner can be recognised from the wrapped seat belt strap around the shaft.
Airbag indicator light permanently lit: read out airbag system fault memory.
72 11 102 Removing and installing or replacing all rear seat belts (compl.,
with lap belt)
Note: Remove rear parcel shelf.
Release screw.
Remove rear right lower strap (2) and middle lower strap (1).
Note:
The ”CENTER” marking is located on the red release button on the
buckle of the lower strap in the middle!
Installation:
Fittings of rear right lower strap (4) and middle lower strap (3) must
rest against stop (1).
Installation position:
Rear right lower strap (4) is shorter and lies underneath middle
lower strap (3), which is longer.
Retaining screw (2) for rear right and middle lower straps.
Tightening torque,
Screw connection for rear right and middle lower straps:

(1) Support ring (fitted to rear right lower strap)
(2) Anchor fitting, rear right lower strap
(3) Anchor fitting, middle lower strap
Installation:
Lug of support ring (1) must snap into opening in anchor fitting of
rear right lower strap (2) and engage in groove of anchor fitting (3).
Release screw.
Remove rear left lower strap (2) and middle lap belt strap (1).
Installation:
Fittings of rear left lower strap (4) and middle lap belt strap (3) must
Rear left lower strap (4) lies underneath middle lap belt strap (3).
Retaining screw (2) for rear left lower strap and middle lap belt strap.
Tightening Torque,
Screw connection for rear left strap and middle lap belt strap:
(1) Support ring (fitted to rear left lower strap)
(2) Anchor fitting, rear left lower strap
(3) Anchor fitting, middle lap belt strap
Installation:
rear left lower strap (2) and engage in groove of anchor fitting (3).
Release retaining screw (1) of right top belt.
Installation:
Contact surface (3) of anchor fitting (4) rests against inside of wheel
arch (2).
Tightening Torque for retaining screw (1),
Release retaining screw (1) of left top belt.

Installation:
arch (2).
Note:
The seat belt can be fitted at rear left or right.
Only the position of the anchor fitting contact surfaces differs:
1. Contact surface for mounting on left side
2. Contact surface for mounting on right side
By way of both contact surfaces (1, 2), it is possible to fit the seat belt on
the left and right sides!
Release retaining screw (1) of left and right automatic reels.

Installation:
During installation, note coding on automatic reel (1) and on body
(2).
Installation:
Automatic reel (2) is behind link (1) on body.

72 11 108 Removing and installing or replacing all rear seat belts (complete,
with retractor belt)
Note: Remove rear shelf.
Unscrew screw.
Remove rear right lower strap (2) and middle lower strap (1).
Note:
The ”CENTER” marking is located on the red release button on the
buckle of the lower strap in the middle!
Installation:
Fittings of rear right lower strap (4) and middle lower strap (3) must
Rear right lower strap (4) is shorter and lies underneath middle
lower strap (3), which is longer.
Retaining screw (2) for rear right and middle lower straps.
Tightening torque,
Screw connection for rear right and middle lower straps:

(1) Support ring (fitted to rear right lower strap)
(2) Anchor fitting, rear right lower strap
(3) Anchor fitting, middle lower strap
Installation:
rear right lower strap (2) and engage in groove of anchor fitting (3).
Unscrew screw.
Remove rear left lower strap (2) and middle lap belt strap (1).
Installation:
Fittings of rear left lower strap (4) and middle lap belt strap (3) must
Rear left lower strap (4) lies underneath middle lap belt strap (3).
Retaining screw (2) for rear left lower strap and middle lap belt strap.
Tightening torque,
Screw connection for rear left strap and middle lap belt strap:
(1) Support ring (fitted to rear left lower strap)
(2) Anchor fitting, rear left lower strap
(3) Anchor fitting, middle lap belt strap
Installation:
rear left lower strap (2) and engage in groove of anchor fitting (3).
Release retaining screw (1) of right top belt.
Installation:
arch (2).
Tightening torque for retaining screw (1),
Release retaining screw (1) of left top belt.

Installation:
arch (2).
Note:
The seat belt can be fitted at rear left or right.
Only the position of the anchor fitting contact surfaces differs:
1. Contact surface for mounting on left side
2. Contact surface for mounting on right side
By way of both contact surfaces (1, 2), it is possible to fit the seat belt on
the left and right sides!
Release retaining screw (1) of left and right automatic reels.

Installation:
During installation, note coding on automatic reel (1) and on body
(2).
Installation:
Automatic reel (2) is behind link (1) on body.

72 11 030 Removing and installing/replacing front seat belt
Caution!
Note safety regulations for handling airbag modules and
pyrotechnical seat belt tensioners,
refer to MG 72
Inexpert handling can trigger off the airbag or the belt tensioner and
thus cause injury.
The plug connections for the pyrotechnical seat belt tensioners are
no longer marked ”Orange”!
To remove and install the seat belt, it is necessary to remove and install
the front seat.
Remove panel for door pillar (top),
refer to 51 43 148.
If the pyrotechnical seat belt tensioner is removed and installed or
replaced, the front seat must be removed and installed.
Remove and install left or right front seat,
refer to Group 52.
Note:
If a seat belt which is damaged due to an accident is exchanged,
always check the seat belt retaining bracket on the seat runner for
damage (bending) and replace if necessary.
A bent seatbelt tensioner retaining bracket on the seat runner may make
it impossible to adjust the height of the seat!
Unscrew bracket.
To do so, release both screws.
Release screw.
Remove reversing clip.
Installation:
Tightening Torque,
Remove sound insulation (1).

Release screw (2).
Installation:
Tightening Torque,
Remove automatic reels.
Installation:
Coding (1) of automatic reels must be situated in opening (2) of
body.
Retaining screw (3) locates automatic reel in position.
If necessary, remove seatbelt height adjustment.

To do so, move seatbelt height adjustment so that both retaining screws
are accessible.
Release both screws.
Installation:
Tightening Torque,
Open cable strap for plug of pyrotechnical belt tensioner (2).
Disconnect plug connection,
refer also to 72 12 ... Unlocking/locking airbag plug connections.
Release screw (3) and remove pyrotechnical belt tensioner.
Installation:
Replace microencapsulated screw.
Tightening Torque for screw (3),
Replace cable strap for plug of pyrotechnical belt tensioner.

Plug of pyrotechnical belt tensioner must not be under strain.
Installation:
Make sure that holder for cable of pyrotechnical belt
tensioner/seatbelt buckle contact is in correct position.
Check retaining bracket (1) of pyrotechnical belt tensioner on seat

runner for damage (bending), replace if necessary.
Repair kit, refer to BMW Parts Service.
To replace retaining bracket, release screw (2) and remove retaining
bracket (1).
Installation:
Tightening Torque,

>

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and electronics >
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AFGS >
72 11 ... Seat belt tensioner (electrical system notes)
Note: The mechanical system is covered separately.
Older systems:
Disconnect the plug connection (1) on the belt tensioner.
2 Bolt for securing the seat belt tensioner
New systems:
Open cable connector (2).
Remove protective cap if necessary.
Disconnect the plug connection (1) on the belt tensioner.
3 Bolt for securing the seat belt tensioner
Important!
Any seat belt tensioner that has activated must always be
renewed.
72 12 ... Airbag system
Function:
refer to 32 34 ...
72 12 ... Deactivation of airbags
Warning!
The responsibility for (de-) activation rests with the customer.
The airbags should always be deactivated if the front
passenger seat is fitted with a child seat.
Customer consent must be documented.
Observe notes and instructions on (de‐) activation procedure.
The following airbags can be (de‐) activated:

Passenger airbag
Side airbag (front passenger), front
Side airbag (front passenger), rear
Important!
Head airbag on passenger side remains active.
R50/R53 From 04/2004 and E83 from 09/2004 only:

For details of deactivation, see following work steps.
R50/R53 From 04/2004 and E83 from 09/2004 only:

see Deactivating front passenger airbag with key-operated switch.

Read and comply with safety regulations
Clamp off battery
Front-passenger airbag Note:

Seat occupancy detector remains connected.
Expose plug connection of passenger airbag

Disconnect plug connection
Tie back disconnected cable and secure with cable strap (rattling
noises)
Stick on warning signs (see below)
Code airbag control unit (see DIS)
Documentation of customer consent and storage in car's file
Entry in car's documents (Germany only)
Replacement of passenger belt with belt force limitation by version
without belt force limitation
Side airbag, front
Expose plug connection of side airbag
Disconnect plug connection of corresponding side airbags
Tie back disconnected cables and secure with cable strap (rattling
noises)
Code airbag control unit (see DIS)
Documentation of customer consent and work in car's file
Side airbag, rear

Expose plug connection of side airbag
Disconnect plug connection of corresponding side airbags
Tie back disconnected cables and secure with cable strap (rattling
noises)
Code airbag control unit (via CIP)
Documentation of customer consent and work in car's file
Warning sign, passenger airbag

Stick on a warning sign (sourcing reference: BMW Parts Service ‐
Component Group 01/Form BMW) with the text ”Passenger airbag
out of operation” from the inside to the top outer edge of the
windshield on the passenger side.
Note:
Remove the warning sign when the passenger airbag is reactivated.
Warning signs, side airbag

Stick on 2 warning signs (sourcing reference: BMW Parts
Service/Component Group 01 ‐ Form BMW) with the text ”Achtung
Warning Side‐Airbag” and ”Side airbag out of operation” to the B‐
pillars (front side airbag) or C‐pillars (rear side airbag) to the nearest
free space below the door lock.
Note:
Remove warning signs when reactivating side airbags.
Passenger Airbag Off light (US version or SA only)
Remove Airbag Off indicator (POL) or trim
Disconnect plug from Airbag Off indicator
Tie back plug and secure with cable strap (rattling noises)
Install trim
Code airbag control unit
Function check airbag warning light (except US version)

The function of the airbag system is checked when the ignition key is
turned in the ignition switch.
Warning lamp lights up: Encoding

before after
1. Airbag warning lamp lights up continuously if an airbag X
is deactivated
2. Airbag warning lamp goes out after several seconds X
when airbags are deactivated
3. Airbag warning lamp goes out after 10 seconds when X X
airbags are activated
Note:
A coding of the airbag control unit must be carried out so that the warning
lamp goes out again after deactivation.
72 12 ... Notes on scrapping vehicles with gas generators (airbag
system)
The gas generator is a pyrotechnical component and is for the most part permanently mounted on the
following components:
Airbag module
Side airbag
Head airbag
Knee airbag
Automatic electric reel
Belt end fitting tensioner
With vehicles which are scheduled for scrapping, it is always essential prior to draining and further stripping
work to ensure that all the gas generators in theÂ vehicle are fired. The fired gas generators can then be
scrapped together with the vehicle.
Firing failure:
If correct firing is not possible, the relevant components must be removed and disposed of by special waste
disposal companies!
Comply with safety regulations for handling airbag system components .
Wait a few minutes before approaching the vehicle
on as used parts.
Firing:
also be observed.
The gas generators must be fired from the outside in this vehicle which has been earmarked for scrapping. In
this process
the doors must be closed
the rear lid must be open
the side windows must be open and
the sunroof must be open
.
To fire the gas generators, use the firing device with the appropriate cables (follow instructions).
Warning!
The burning of solid fuel will heat up the airbag unit - danger of burning hands!
Components
Procedure
components.
Read fault memory
Rectify faults
Delete fault memory
Delete fault memory
Seat belt system
Components
Automatic reel
Seat belt tensioner
Seat belt buckle
Procedure
Seats
Components
Seat
Airbag module
Procedure
Driver's airbag
Components
Airbag module
Steering Wheel
Procedure
Components
Airbag module
Procedure
Components
Airbag module
Door trim panel
Door in white
Seat
Procedure
Head airbag
Components
Airbag module
A-pillar trim panel
Roofliner
Procedure
Knee airbag
Components
Procedure
Components
Procedure
72 12 020 Removing and installing / replacing left or right ITS head airbag
(model without slide/tilt sunroof)
Warning!
Observe safety precautions for handling airbag modules and
refer to MG 72
If the ITS head airbag is damaged during removal or installation, it
must be replaced.
A damaged ITS head airbag exhibits an impaired protective function
and in extreme cases loses its protective function altogether.
Remove headliner,
Version without slide/tilt sunroof,
refer to 51 44 001
Remove trim for instrument panel,
refer to 51 45 030
Installation summary, retaining elements, ITS head airbag, E46 Saloon/Touring

1 Retaining screw, A-pillar (front) 5 Bracket for front grab handle
2 Retaining clips, retainer, trim panel, A-pillar 6 Bracket on B-pillar
3 Retainer, A-pillar, front 7 Bracket, grab handle, rear
4 Retainer, A-pillar, rear 8 Retaining screw, rear
Important!
When removing ITS head airbag, do not damage
ITS head airbag
Windshield
retainer, trim panel, A-pillar
Note:
Gas generator version up to 07 / 98
View of retaining clip for gas generator plug:

Arrows point to retaining lugs.
Applying a screwdriver to one side of retaining clip for gas generator plug,
gently press together and remove a little.
Proceed in same way on other side.
Remove retaining clip for gas generator plug.
Installation:
Make sure retaining clip for gas generator plug is correctly seated.
Retaining clip engages audibly into place!
Disconnect plug for ITS head airbag gas generator.
Slacken nut (1).

Remove gas generator, ITS head airbag (2).
Installation:
Replace self-locking nut (1).
Tightening torque,
Installation:
Lug (1) of ITS head airbag gas generator must be fixed in position in
bore (2) in support tube (3)!
Note:
Gas generator version as of 07 / 98
The gas generator, ITS head airbag, will be altered from 07 / 98.
The altered ITS head airbag gas generator has as its upper attachment
point a bore (1) for attachment to the instrument panel support tube.
Lower mounting point (2) is designed as a pin for securing in support tube
for instrument panel.
Support tube for instrument panel from 07 / 98:
1. Threaded pin for attaching ITS head airbag gas generator
2. Bore for locating retaining pin for ITS head airbag gas generator
Disconnect plug for ITS head airbag gas generator,

refer also to 72 12 ... Unlocking/locking airbag plug connections
Unfasten nut.
Remove ITS head airbag gas generator.
Installation:
Tightening torque,
Gas generator as of 07 / 98:

1. Bore for accommodating threaded pin of gas generator, ITS head
airbag, on support tube for instrument panel
2. Locating pin on gas generator, ITS head airbag, for securing to
support tube for instrument panel
Installation:
The threaded pin for securing the ITS head airbag gas generator to
the instrument panel support tube must be secured in the bore in
the ITS head airbag gas generator (1).
The locating pin on the ITS head airbag gas generator must be
secured in the instrument panel support tube (2).
Note:
If a gas generator of the version up to 07 / 98 is replaced by a gas
generator of the version from 07 / 98, it is necessary to make
modifications to the support tube for instrument panel.
The plug has likewise been changed and the cable length must be
extended by approx. 250 mm to accommodate the altered gas
generator.
Procedure for extending airbag cables is the same as the

procedure for cable repairs:
If wiring harness is visibly damaged,
refer to 72 12 ... Repairing airbag cables
The altered ITS head airbag gas generator has as its upper attachment
point a bore (1) for attachment to the instrument panel support tube.
Lower mounting point (2) is designed as a pin for securing in support tube
for instrument panel.
1. Insert an M 6 X 15 screw (1) in previous upper locating bore of ITS

head airbag gas generator, refer to BMW Parts Service.
2. Drill out previous threaded pin for attaching ITS head airbag gas
generator and replace with a hole
6.5 mm in dia. (2).
Also check whether the changed version of the ITS deflector plate as of
07/98 is fitted.
1 = ITS deflector plate up to 07/98
2 = ITS deflector plate, changed version
as of 07/98
If an ITS head airbag gas generator of the version as of 07/98 is fitted, fit
the ITS deflector plate in its changed form (2) as of 07/98 without delay.
Only the changed ITS deflector plate (2) as of
07/98 is still supplied as a spare part.
Note:
If it is necessary to fit an ITS deflector plate in its changed form, it is
absolutely essential to fit an altered B-pillar trim at the top!
The scope of parts
ITS deflector plate
Trim, B-pillar, top
Expansion rivet (for securing deflector plate ITS)
can be found in the EPC (Electronic Parts
Catalog).
ITS deflector plate up to 07/98.

Only one lug (1) for securing to B-pillar trim at top.
ITS deflector plate up to 07/98 fitted on B-pillar.

ITS deflector plate, changed version as of 07/98.
Two lugs (1) for securing to B-pillar trim at top.
ITS deflector plate, changed version as of 07/98, fitted on B-pillar.
Removing ITS deflector plate, version up to 07/98 shown here:

Unscrew bolt (1).
Slide ITS deflector plate upwards.
Remove ITS deflector plate towards front.
View, B-pillar without ITS deflector plate.

1 = Bore for expansion rivet for additional mounting of ITS deflector plate
in modified version from 07 / 98.
Note:
The conversion work ends here.
Note:
Gas generator version as of 07 / 99
The gas generator, ITS head airbag, will be altered from 07 / 99.
The modified ITS head airbag gas generator has two locating lugs (1) as
locating fixtures and an oval bore (2) as mounting point for securing to
support tube for instrument panel.
The oval bore (2) for securing to the support tube for instrument panel
corresponds in principle to the mounting of the gas generator from 07 /
98.
Support tube for instrument panel from 07 / 99:

1. Threaded pin for attaching ITS head airbag gas generator
2. Bore for accommodating locating lugs of ITS head airbag gas
generator
Disconnect plug for ITS head airbag gas generator, refer also to 72 12 ...
Unlocking/locking airbag plug connections
Slacken nut (1).

Swivel ITS head airbag gas generator to one side (2) and remove
towards rear (3).
Installation:
Installation:
The two locating lugs (1) on the ITS head airbag gas generator must
be secured in the two bores in the support tube for instrument panel
(2).
Installation:
During installation, the ITS head airbag gas generator does not rest flush
on the support tube for instrument panel; there is an intentional gap (A).
Tightening the self-locking nut builds up a desired pretension, which
servers as additional security against release.
Note:
If a gas generator of the version up to 07 / 98 or up to 07 / 99 is
replaced by a gas generator of the version from 07 / 99, it is
necessary to make modifications to the support tube for instrument
panel.
A precondition for the modifications to be carried out on the instrument

panel support tube is the presence of the threaded pin (1) for securing
the ITS head airbag gas generator.
When converting a version of the ITS head airbag gas generator up to 07
/ 98, observe the following
It is not necessary for the bore (2) for securing the ITS head airbag gas
generator to be present.
Make sure there is a flat contact surface of the ITS head airbag gas
generator on the instrument panel support tube.
The modified ITS head airbag gas generator has two locating lugs (1) as
locating fixtures and an oval bore (2) as mounting point for securing to
support tube for instrument panel.
The oval bore (2) for securing to the support tube for instrument panel
corresponds in principle to the mounting of the gas generator from 07 /
98.
Two 8.5 mm dia. bores must be drilled in the instrument panel support
tube.
Mark out measurements for both bores on instrument panel support

tube.
Height measurement (center bore) of lower bore:
Measurement (A) = 25 mm from lower edge of sheet metal into which
both bores are drilled.
Height measurement of upper bore:
Measurement (A) = 47 mm from lower edge of sheet metal into which
both bores are drilled.
Mark out measurements for both bores on instrument panel support

tube.
Side measurement of lower bore:
Measurement (D) = 11.0 mm from edge of sheet metal into which both
bores are drilled.
Side measurement of upper bore:
Measurement (D) = 10.5 mm from edge of sheet metal into which both
bores are drilled.
Note:
Make sure there are no lines or other equipment components which
could be damaged in the area of the marked bores.
If necessary, remove or protect existing components.
Draw off swarf when drilling.
Drill two 8.5 mm dia. bores (1, 2) at the marked points in the instrument
panel support tube.
Deburr bores and protect against rust.
Note:
A bracket (1) for the instrument panel trim is spot-welded to the
instrument panel support tube on LHD vehicles on the right (in direction
of travel) and on RHD vehicles on the left (in direction of travel).
The two bores (1) for securing the ITS head airbag gas generator from 07
/ 99 are seated in the direct vicinity of the welding spots for the bracket
for the instrument panel trim (2).
After drilling the two bores (1) for securing the ITS head airbag gas
generator from 07 / 99, it is absolutely essential to check the strength of
the welding spots for the bracket for the instrument panel trim (2); if
necessary, reweld or reset the welding spots.
Note:
If a gas generator of the version up to 07 / 98 is replaced by a gas
generator of the version from 07 / 99, it is necessary to make further
modifications.
The plug for the ITS head airbag gas generator has been changed and
the cable length must be extended by approx. 250 mm to accommodate
the altered gas generator.
Procedure for extending airbag cables is the same as the
procedure for cable repairs:
In event of visible damage to wiring harness, refer to 72 12 ... Repairing
airbag cables.
Also check whether the changed version of the ITS deflector plate as of
07/98 is fitted.
1 = ITS deflector plate up to 07/98
2 = ITS deflector plate, changed version
as of 07/98
If an ITS head airbag gas generator of the version as of 07 / 99 is fitted, fit
the ITS deflector plate in its changed form (2) without delay.
Only the changed ITS deflector plate (2) as of
07/98 is still supplied as a spare part.
Release retaining screw, A-pillar.

Note:
Screw is held in end fitting by locking washer.
Installation:
Tightening torque,
View of mounting bolt on A-pillar with end fitting of ITS head airbag
1. End fitting of ITS head airbag
2. Lock washer
3. Mounting bolt on A-pillar
Release rear retaining screw (1).

Note:
Bolt is held in end fitting (2) by retaining disk.
Installation:
Tightening torque,
View of rear retaining screw with end fitting of ITS head airbag
1. End fitting of ITS head airbag
2. Lock washer
3. Retaining screw, rear
Remove ITS head airbag from rear grab handle bracket towards
bottom.Important!
Do not damage the ITS head airbag in the process!
Installation:
Ensure that ITS head airbag is correctly positioned in rear grab
handle bracket.
Retaining clip (2) of rear grab handle retainer (1) must be above ITS head
airbag (3).Important!
The retaining clip (2) must not have any sharp edges in the area of
the ITS head airbag!
Danger of damage to the ITS head airbag!
Replace bracket for rear grab handle if necessary.
Unscrew bolt (1).

Push bracket on B-pillar upwards (2).
Remove retainer, B-pillar, towards front (3).
Installation:
Tightening torque,
During installation, ensure that retaining lug is correctly seated in
body.
View of bracket on B-pillar
1. Retaining bore for retaining lug of B-pillar bracket in body
2. Retaining lug on bracket on B-pillar
must engage in mounting hole
3. Bracket on B-pillar
4. ITS head airbag
Remove ITS head airbag from front grab handle bracket from
below.Important!
Do not damage the ITS head airbag in the process!
Installation:
Pay attention to correct position of ITS head airbag in bracket of
front grab handle.
Retaining clip (2) of front grab handle retainer (1) must be above ITS
head airbag (3).Important!
The retaining clip (2) must not have any sharp edges in the area of
the ITS head airbag!
Danger of damage to the ITS head airbag!
Replace bracket for front grab handle if necessary.
Unscrew bolt (1).

Push retainer, A-pillar, rear, towards top (2).
Remove retainer, A-pillar, rear, towards front (3).
Installation:
Tightening torque,
During installation, ensure that retaining lug is correctly seated in
body.
View of retainer, A-pillar, rear
1. Retaining bore for retaining lug of retainer, A-pillar, rear in body
2. Retaining lug on retainer, A-pillar, rear,
3. Retainer, A-pillar, rear
4. ITS head airbag
Unclip cable holder and pull cable down slightly so that screw (1)
becomes accessible.
1. Securing screw for retainer, A-pillar, front, of ITS head airbag
2. A-pillar wire harness
3. ITS head airbag
4. Retainer, A-pillar, front
Unscrew bolt (1).

Push retainer, A-pillar, front, towards rear (2).
Remove retainer, A-pillar, towards front (3).
Installation:
Tightening torque,
During installation, ensure that retaining lug is correctly seated in body.
View of retainer, A-pillar, front

1. Retaining bore for retaining lug of retainer, A-pillar, front, in body
2. Retaining lug on retainer, A-pillar, front,
3. Retainer, A-pillar, front
4. ITS head airbag
Fold ITS head airbag forward so that expansion rivet is freely accessible.
If necessary, remove cover above head of expansion rivet.
Pull out head (1) of expansion rivet (2) towards top.
Remove expansion rivet towards top.
Installation:
Replace expansion rivet.
If a cover is fitted above the head of the expansion rivet, it must be
refitted.
Replace damaged cover.
Unclip A-pillar wiring harness from retaining lugs of retainer, trim panel, A-
pillar.
Position of retaining clips, retainer, trim panel, A-pillar.
Important!
When removing retainer, trim panel, A-pillar, it is absolutely essential
to avoid
damage to paintwork,
damage to retainer, trim panel, A-pillar,
damage to windshield,
damage to ITS head airbag!
Remove retainer, trim panel, A-pillar.
To do so, insert screwdriver (2) in area of retaining clip between retainer,
trim panel, A-pillar (1) and body (3) and unclip retaining clip.
Perform this procedure on all retaining clips.
Installation:
Replace all retaining clips that have been removed.
1. retainer, trim panel, A-pillar

2. Screwdriver
3. Body (A-pillar)
Remove ITS head airbag.
72 12 000 Removing and installing or replacing airbag module on passenger
side
Warning!
Observe safety regulations on handling airbag modules and
pyrotechnic belt tensioners,
refer to main group 72
Improper handling may trigger the airbag and as a result cause
injuries.
Warning!
Replace the front passenger airbag cover (airbag lid) after each
airbag deployment!
We cannot rule out that the retaining straps of the airbag lid have
been damaged by airbag deployment.
We cannot guarantee correct function of the retaining straps when
reusing a possibly damaged airbag lid.
Important!
Do not damage the dashboard trim panel when removing the front
passenger airbag cover (airbag lid).
Remove right fresh air grille,

refer to 64 22 136.
Position of the retaining clip of the front passenger airbag cover.

From 10/98, an additional retaining lug was fitted to the front passenger
airbag cover.
This additional retaining lug is located at the top left in the rounded area.
Additional retaining lug at the front passenger airbag cover.
Retaining clip for additional lug at the front passenger airbag cover in the
dashboard trim panel.
Note:
We will only supply the front passenger airbag cover fitted as from
10/98 (with additional retaining lug) as a spare part.
In vehicles produced up to 10/98, there is no standard retaining clip for

this retaining lug in the dashboard trim panel.
In this case it is permitted to cut off the present additional retaining lug
flush and burr-free with the front passenger airbag cover.
Important!
Pay attention to the additional retaining lug when levering out the
front passenger airbag cover in vehicles produced from 10/98!
Lever out the front passenger airbag cover (1).Note:

Retaining clip remains in the dashboard when removing the cover.
Undo screws (1) and place the front passenger airbag cover (2) on top.
Tightening torque,
refer to technical data 72 12 10 AZ
Installation note:
Front passenger airbag cover (3) must engage into the all-round
groove (1) of the dashboard with the lug (2).
Installation note:
The additional retaining lug at the front passenger airbag cover must
engage in the retaining clip of the dashboard trim panel.
Undo screws (1) at the front passenger airbag module.
Tightening torque,
Note:
Do not tension the cable when removing the front passenger airbag
module (1)!
Lift front passenger airbag module (1) and move sideways:

- Open lock by pressing on the tab (2)
- Disconnect plug connectionÂ (3)
refer to 72 12 .. Unlocking/locking airbag plug connections
- Remove front passenger airbag module (1).
Important!
Always fit the front passenger airbag module matching the
corresponding vehicle!
Never fit a two-stage front passenger airbag module if a single-
stage front passenger airbag module has been specified for
installation!
Always fit an adapter cable if this is specified in the ETK (Electronic
Parts Catalogue)!
Distinction between single-stage and two-stage front passenger
airbag module with six-pin connector for the front passenger airbag
module:
Feed line for single-stage front passenger airbag module, one cable
only in the connector of the front passenger airbag module!
Feed line in two-stage front passenger airbag modules, two cables
in connector of the front passenger airbag module!
Installation note:
Upon replacement of the front passenger airbag module, fit the front
passenger airbag module specified in the ETK (Electronic Parts
Catalogue) after having entered the vehicle chassis identification number
into the ETK.
Distinction between single-stage and two-stage front passenger airbag
module with six-pin connector for the front passenger airbag module:
1 = Feed line for single-stage front passenger airbag module, one cable
only in the front passenger airbag module connector!
2, 3 = Feed line for two-stage front passenger airbag module, two cables
in the front passenger airbag module connector!
Pull off the retaining tube (1) from the stud bolt (2) and completely
remove the cover (3).
Insert screwdriver into the retaining clip (1) for the holding clip (2) of the
front passenger airbag cover.
Turn the screwdriver slightly so that the clamp (1) is opened and the
retaining clip (2) can be removed.
Remove the upper part of the faulty retaining clip from the front
passenger airbag cover.
Insert new retaining clip into the front passenger airbag cover.
72 12 010 Removing and installing/replacing airbag module on left or right
front door
Caution!
pyrotechnical seatbelt tensioners,
refer to MG 72
Removing and installing front left or right door trim,

refer to 51 41 000
Unfasten screws and remove airbag module.

Caution!
Always replace micro-encapsulated screws!
Tightening Torque,
Withdraw airbag cable from retainer on airbag module.

Installation:
During installation, make sure plug (1) snapped correctly into place
in gas generator.
72 12 015 Removing and installing/replacing airbag module on left or right
rear door
Caution!
pyrotechnical seatbelt tensioners,
refer to MG 72
Remove and install rear left or right door trim,

refer to 51 42 000.
Unfasten screws (1) and remove airbag module.

Caution!
Always replace micro-encapsulated screws!
Tightening Torque,
Pull off connector (1) for side airbag on side airbag module.
72 12 025 Removing and installing/replacing left or right ITS head airbag
(model fitted with sliding/tilting sunroof)
Caution!
refer to MG 72
Remove headliner,
refer to 51 44 011
Remove trim for instrument panel,
refer to 51 45 030
For details on how to proceed, refer to:

72 12 020 Removing and installing left or right ITS head airbag (model not
fitted with sliding/tilting sunroof),
refer to 72 12 020
Important!


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AFGS >
72 12 ... Safety regulations for handling airbag modules, airbag
components and pyrotechnical seat belt tensioners
refer to 32 34 ...
physical injury!
Head airbag (ITS)
law of 13/09/1976).
regulations.
Service.
waiting period:
Danger of injury!
Disconnect battery
2. Transport
3. Storage
regulations.
generators
Important!

Head airbag
1. Regulations
Service.
BMW ISTA.
Disconnect battery
3. Transport
4. Storage
regulations.
72 12 ... Scrapping vehicles with passenger airbag and pyrotechnic
belt tensioners
refer to 32 34...
72 12 ... Unlocking/locking airbag plug connections
Warning!
Important!
An airbag plug connection must be replaced if it is damaged.
Sourcing reference for airbag repair instructions (with plug
connection), refer to BMW Parts Service.
Following versions of plug connections on airbag module/gas generator

are possible:
Airbag plug connection on gas generator/airbag module is offset by
90°
Airbag plug connection on gas generator/airbag module is straight
(3 versions)
Airbag plug connection on gas generator/airbag module offset by 90°:

There are two ways of unlocking this airbag plug connection on the gas
generator/airbag module:
Method 1:
Simultaneously pull cover (1) upwards at lugs on left and right (2).
Method 2:
Insert a narrow screwdriver into recess (1) in housing (2).
Carefully prise cover (3) off (4).
Cover (1) is not positioned higher than housing (2).
The airbag plug connection is unlocked and can now be detached from
the gas generator/airbag module.
Installation:
After attaching airbag plug connection to gas generator/airbag module,
press cover (1) downwards until it rests flat on housing.
Check that it catches properly.
Airbag plug connection on gas generator/airbag module is straight (2

versions)
Version 1:
Press locking/unlocking plate (1) at edge (4).
Locking/unlocking plate (1) snaps upwards at opposite edge (3) and
releases detent lug (2).
The airbag plug connection is unlocked and can now be detached from
the gas generator/airbag module.
Installation:
After attaching airbag plug connection to gas generator/airbag module,
check whether detent lug (2) is visible in opening of locking/unlocking
plate (1).
Only if the detent lug (2) is visible will the airbag plug connection gas
generator/airbag module be correctly engaged.
Version 2:
Press locking/unlocking plate (1) on edge (3) and pull plug (2) out of plug
housing (4).
Installation:
Only if the detent lug is visible in opening (5) will the gas generator/airbag
module plug connection be correctly engaged.
Version 3:
Press lock button (1) and pull out plug (2) up to initial engagement
position.
Detach plug (2) from firing pellet.
Installation:
Insert plug connection in initial engagement position in gas
generator/airbag module and engage in final engagement position.
Illustration of version 3 with gas generator:

A. Initial engagement position
B. Final engagement position
1. Lock button
2. Gas generator
Version 4 - Crash-active head restraint:
Press locking clip at edge and disconnect plug (1).
Installation:
Check for correct engagement.
72 14 ... Replacing outer/inner Isofix holders
Arrangement of holders for Isofix:

1 Outer Isofix holder
2 Inner Isofix holder
Remove cover of holders.

Release screw (1).
Installation:
Tightening torque = 31 Nm.
Installation:
Push on catches (2) of cover (1) over pin (3).

temperature.
Installation note:
curing)

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AFGS >
84 11 530 Removing and installing / replacing interface for D-Network car
phone
Remove and install center console,

refer to 51 16 200.
Unfasten plug connection (1). Unclip bracket (2). Remove interface (4).
Installation:
Ensure guide (3) is correctly seated.
84 11 500 Removing and installing / replacing telephone handset with
keypad
Remove and install/replace eject box,

refer to 84 11 510.
Unclip cable duct (1) in direction of arrow and remove telephone handset
with cable. Disconnect plug.
84 11 610 Removing and installing/replacing eject box (cordless keypad
handset)
Unlock insert in storage tray (1) on both sides in direction of arrow and
remove upwards from storage tray (2).
Push foam insulation (1) back a little and disconnect plug connection (2).
Remove insert in storage tray (3).
Unlock retainer (1) on both sides and remove eject box (2) in direction of
arrow from insert in storage tray (3).
84 11 510 Removing and installing/replacing eject box (fixed mounting)
Note:
Removing insert in storage tray.
Remove insert in storage tray (1) in direction of arrow from storage
tray (2).
Unlock retainer (1) in direction of arrow. Disconnect plug connection (2).
Unhook cable duct (1) in direction of arrow and remove eject

box (2).Installation:
Replacement:
84 11 510 Removing and installing/replacing eject box (mobile phone)
Unlock insert in storage tray (1) on both sides in direction of arrow and
remove upwards from storage tray (2).
Disconnect plug connections (1), (2) and (3).

Remove insert in storage tray (4).
Unlock retainer (1) on both sides and remove cable duct (2) in direction
of arrow from insert in storage tray (3).Installation:
Remove eject box (1) in direction of arrow from insert in storage tray (2).
Replacement:
Cut off plastic ribs (1) from telephone console insert (2) with a suitable
tool in area (3) and discard.
Deburr telephone console insert (2) in area (3) with a file.
Connect plug connection from vehicle to eject box with adapter

lead (1).Important!
Lay and secure plug and lead without rattling in centre console.
84 11 550 Removing and installing/replacing hands-free microphone

64 1 020
Important!
Disconnecting the plug connection for the hands-free microphone or
emergency SOS call button results in fault memory entries in the
telephone control unit (limitation in the emergency SOS call
system).
After fitting, read out fault memory and if necessary delete entries.
Model without slide/tilt sunroof:

Lever out microphone trim (1) with special tool 64 1 020 in direction of
arrow and remove.
Replacement:
Unclip hands-free microphone (1) and remove from microphone trim (2).
Installation:
Arrow (3) of hands-free microphone (1) and arrow (4) of microphone
trim (2) point in driving direction.
Version with slide/tilt sunroof:

Lever out microphone trim (1) with special tool 64 1 020 in direction of
arrow and remove.
Replacement:
Unlock detent lug (1) and feed out hands-free microphone (2) in direction
of arrow.
Installation:
Arrow on hands-free microphone (2) points in driving direction.
84 11 520 Removing and installing/replacing transceiver (fixed mounting)
Detach left trunk wheel arch trim in rear area.
Loosen screws (1).

Pull out holder for transmit-receive unit (2) in direction of arrow and
disconnect plug connections (3).
Replacement only:
Release screw (1).
Unhook mounting bracket (2) and remove.
Remove transmit-receive unit (4) from holder for transmit-receive unit (3).
Installation:
If necessary, replace sealing strip stuck to holder for transmit-receive
unit (3)
84 11 600 Replacing cordless keypad handset
Refer to Supplement to Owner's Manual:

Operating instructions for BMW car phone.
84 21 530 Removing and installing/replacing hands-free charging
electronics (cellular phone)
Convertible only:
Remove line compensator.
All:
Remove transmit-receive unit.
84 31 020 Removing and installing/replacing hands-free system speaker
Remove trim for pedal assembly.

Screw off threaded ring for speaker (2) in direction of arrow and remove
hands-free system speaker (3) towards bottom.
Installation:
Make sure hands-free system speaker (1) is correctly positioned in
panel for pedal assembly.
84 50 050 Removing and installing / replacing basic antenna
Remove oddments tray.
Disconnect plug connection (1) and remove basic

antenna (2).Installation:
Make sure basic antenna (2) is correctly positioned.
Replacement:
Unscrew nuts (1).
Remove basic antenna (2) from holder (3).
84 50 035 Replacing multiband telephone antenna

00 9 317
51 3 050
Note: Clean rear window.
Mark position of multiband telephone antenna (1) as illustrated with aid of

a strip of adhesive tape (2).
Release knurled nut and disconnect antenna plug connection (1).
Detach rubber grommet (1) and remove disconnected antenna lead from
luggage compartment.
Installation:
Make sure rubber grommet (1) is correctly seated.
Pull antenna lead up to multiband telephone antenna out of window seal.
Carefully heat car roof in antenna area with a hot air blower (max.
50°C).
Slowly lift off multiband telephone antenna (1) from rear window with
Caution!
Risk of damage!
Do not under any circumstances treat adhesive residue with
scratching, sanding or paint-dissolving materials.
Remove adhesive residue with spirit only; remove larger residues
with adhesive remover (from EPC).
Installation:
If necessary, remove adhesive coating of antenna lead (1) with adhesive
remover (from EPC).
Insert antenna lead (1) to approx. 15 cm length from center of car with
special tool 51 3 050 under window seal.
Lay remaining antenna lead (1) in window seal only after multiband
telephone antenna (2) has been stuck on.
Lay antenna lead (1) so as to avoid kinking, scuffing and crushing.
Make sure window seal is correctly seated.
Installation:
Temperature of car roof and multiband telephone antenna must be at
least 18°C.
Clean bonding surface on car roof with spirit and allow to dry (drying time
at least 1 minute).
Then dot touch bonding surface after this point.
Detach protective film of multiband telephone antenna (1).

Note:
Do not touch bonding surface of multiband telephone antenna (1).
Attach multiband telephone antenna (1) centrally from rear to roof edge
and then place in position.
Check correct position in accordance with marking (2), correct if
necessary.
Note:
Change position of multiband telephone antenna (1) max. three times so
as not to impair adhesive effect of adhesive.
Press down telephone antenna (1) at small intervals (1-2 cm) all round
with firm thumb pressure.
Note:
To guarantee a permanent bond:
Once it has been pressed down, the telephone antenna must not
be reattached after it is detached.
Only use washing installations after a period of 24 hours has
passed.
equipment)
Warning!
Important!
direct sunlight.
Important!
Important!
fumes directly.
agent/paint.
cream.
Important!
First Aid:
Recycling:
sees fit.
equipment)
Warning!
Important!
direct sunlight.
Important!
Important!
fumes directly.
agent/paint.
cream.
Important!
First Aid:
Recycling:
Warning!
damage.
Attention!
agents !
Warning!

Suitable gloves
Apron
Rubber boots
Ear protectors
Safety shoes
Attention!
engine
washes.
tyre valves.
Attention!
Remedy:
temperature sensor.
Important!
glass.
30 to 40 μm).
Hardening time:
Important!
sees fit.
equipment)
Warning!
Important!
direct sunlight.
Important!
Important!
fumes directly.
agent/paint.
cream.
Important!
First Aid:
Recycling:
Warning!
damage.
Attention!
agents !
Warning!

Suitable gloves
Apron
Rubber boots
Ear protectors
Safety shoes
Attention!
engine
washes.
tyre valves.
Attention!
Remedy:
temperature sensor.
Important!
glass.
30 to 40 μm).
Hardening time:
Important!
00 26 11 (731)
Brake fluid - Operating Fluids Specification
Situation: To provide permanent surface protection in the brake system, only low viscosity DOT4
brake fluids that have been approved by BMW may be used.
Vehicles concerned:All BMW, MINI and Rolls-Royce.
Procedure: The low viscosity DOT4 brake fluids currently approved by BMW can be viewed in the
current ISTA version (operating materials - main group 34).
00 12 11 (696)
Brake fluid service - extension of the first brake fluid interval to 36 months
Without US
Situation: Beginning with production date 03/2011, the 1st brake fluid interval is being extended from
24 months to 36 months in all current vehicle types. After the first brake fluid renewal, an
interval of 24 months each applies.
New vehicle series introductions are already equipped with the extended 1st brake fluid interval (36 months).
Vehicles concerned:from 03/2011
MINI R55, R56, R57 and R60
BMW 1 Series E81, E82, E87 and E88
BMW 3 Series E90, E91, E92 and E93
BMW X1 E84
BMW Z4 E89
from 04/2011
BMW X5 E70, E71 and E72
from 07/2011
BMW 6 Series F12 and F13
from 09/2011
BMW 7 Series F01, F02, F03 and F04
BMW 5 Series GT F07
BMW 5 Series F10 and F11
Rolls-RoyceRR4
from 10/2011
BMW X3 F25
BMW 5-SeriesF18
Procedure: The maintenance work must be carried out as shown in the Commercial Service Data and
ISTA.
00 06 10 (642)
Brake fluid service – "Bonnet gas strut" check with active pedestrian impact
mitigation (SA8TF)
excluding US vehicles
Situation: Thanks to the introduction of the technically enhanced generation of the pedestrian
protection as of 03/2011, safety-related components are being installed in the vehicle. To
reliably guarantee fulfilment of safety requirements in the long term, specific components
have to be replaced regularly. The regular check and/or replacement of these components is carried out in the
context of a maintenance visit.
In vehicles prior to the version (build date) specified no check is required or the gas pressure springs have to
be replaced.
Vehicles concerned:All vehicles with active pedestrian protection (SA8TF)
Measure: Attention!
Expiry date present on gas pressure spring for bonnet:
Check the expiry date of the engine compartment lid gas pressure springs (1) at every brake fluid renewal.
The expiry date of the two engine compartment lid gas pressure springs (1) must extend to the time of the
next brake fluid service (24 months). If the expiry is before that date, both engine compartment lid gas
pressure springs (1) have to be replaced at extra charge.
Attention!
If no expiry date is present on gas pressure spring for bonnet:
The imprint of the expiry date on the gas pressure springs is no longer present in all models. For vehicles with
the SA8TF "Active pedestrian protection", still a regular replacement of the gas pressure springs is necessary
as part of the maintenance!
For vehicles with the SA8TF "Active pedestrian protection", front compartment lid gas pressure springs are to
be renewed starting from the production date of the vehicle in the interval of 5 years at the latest.
=> Renew both front compartment lid gas pressure springs for each second service of brake fluid (approx. 4 to
5 years).
Procedure: The procedure for replacing the front compartment lid gas pressure springs can be found
in the repair instructions on ISTA.
00 17 17 (475)
CBS general - Reset is lost
Situation: Field feedback has shown that a CBS reset carried out on the vehicle can be lost.
The fault occurred under the following conditions:
When the vehicle goes into sleep mode there is an undervoltage
Vehicle is programmed directly after CBS reset without going into sleep mode
Vehicles concerned:All
Procedure: Avoid the conditions specified above.

00 47 14 (138)
Engine oil - varying colours/ smell after initial filling in the works
Situation: In engine works a few engines are subject to a hot test. To be able to detect possible oil
leakages, fluorescent agent is mixed with the engine oil. This agent causes discolouration
of the engine oil. Depending on the mixture ratio the engine oil can take a red colour or
green/yellow colour and smell like automatic transmission fluid.
The addition of fluorescent agent has no impact on the consistency and the characteristics of the engine oil.
Since only engine oil may be kept exclusively in the engine works, a false filling cannot be possible from the
technical side.
Vehicles concerned:BMW, MINI and Rolls-Royce
Procedure: The fluorescent agent remains in the engine and is washed out during the first engine oil
change.
An engine oil change in connection with the above mentioned complaint is not allowed!
Â
00 15 16 (388)
Engine oil service - countries with higher levels of dust: Check the air filter element for
contamination
Situation: To guarantee the customer's mobility, in countries with higher levels of dust the air filter
element should be checked for contamination at each engine oil service.
Vehicles concerned:BMW
MINI
Rolls-Royce
Procedure: In countries with higher levels of dust:
Check the air filter element (intake silencer) for contamination at each engine oil service.
If there is significant contamination, the change interval must be accordingly reduced.
00 30 11 (735)
Final drive oil - new oil quality from 07/2011
Situation: In motor vehicles from production date 07/2011, the final drive oil SAF-XO is being
replaced by the final drive oil Hypoid Axle Oil G1 (BOT448).
Vehicles concerned:All BMW without M models
All MINI
All Rolls-Royce
Procedure: In vehicles from production date 07/2011, use oil specification Hypoid Axle Oil G1
(BOT448) for oil filling/additions to the rear axle differential.
The final drive oils currently approved by BMW can be viewed in the current ISTA version
(operating materials - main group 33).
36 04 16 (367)
Handling fault messages / Check Control messages for Run Flat Indicator RDC
(SA2VB)
Situation: Since 2014 the standard equipment of all new vehicles covers a tyre pressure
display RDC (SA2VB) for each individual wheel. Sensors on all four wheels enable a
precise and individual monitoring of the tyre pressure. In case of a pressure deviation, the
driver is notified early. In order to not unsettle customers, three levels were created for the KOMBI messages.
These appear as follows:
First level of message:
The first level is only information for the customer, that the tyre pressure has dropped due to natural diffusion.
There are no technical problems and one can continue driving without any concerns. For this reason, only one
information symbol can be seen in the KOMBI.
The Check Control message can appear as follows (example in German and English):
Second level of message:
The message of the second level takes place if the tyre pressure has dropped below the legal threshold
value and limits the comfort and safety of the customer. Accordingly, a Check Control message and a yellow
warning light can be seen in the KOMBI. However, one can continue driving moderately, but the tyre pressure
should be corrected as soon as possible.
The Check Control message can appear as follows (example in German and English):
Third level of message:
If the tyre pressure drops too much, the yellow warning light is displayed. The customer should perform a
visual check of the tyres and correct the tyre pressure if possible.
Here is an example of the message for the front left tyre (example in German and English):
Vehicles concerned:BMW, MINI and Rolls-Royce with SA2VB
Procedure: All three Check Control messages are notices for the dropped tyre pressure. The RDC
system thus works correctly and trouble-free. An OBD diagnosis is never necessary, as
no fault memory (DTC) is created.
The customer is informed that only the tyre pressure should be corrected and reset via the CID.
For the second and third level, the tyre and valve must also be checked for tightness and damages, for this
also see PuMA measure 60186974.
00 41 11 (773)
Ignition key data tapping on CBS vehicles
Situation: In the interests of simplifying the service reception, the current vehicle data (e.g. CBS
remaining values) are stored in the ignition key used last.
Note: The ignition key is overwritten with the current data during a journey at specific
intervals. As this writing process is repeated only after a defined distance, the key data may differ at service
reception slightly from the most up-to-date vehicle data.
If a spare key with an outdated data status is handed over to the Service Advisor, it must be updated in the
vehicle before service reception.
Procedure: The process for writing the current vehicle data to the ignition key can be activated
manually in the vehicle.
Data tapping in vehicles with key slot (E Series and MINI):
Sit in the vehicle and closed the door.

Note:
Check the currency of the date and time settings in the vehicle.
Insert the ignition key (1) into the ignition slot (2) until it is locked.
Note:
The vehicle displays turn on.
Press button combination:

1. Press and hold down central locking (1).
2. Also press start/stop button (2).
3. Release start/stop button (2).
4. Release central locking (1).
An acoustic signal after approx. 10-15 seconds denotes the end of data transfer.
Note:
Acoustic signal immediately after data tapping indicates a fault message. The process must be
repeated.
Data tapping in vehicles with no key slot (F Series):
Press start/stop button (1) twice.

Note:
Make sure the display screen switches on.
2. Also press start/stop button (2).
3. Release start/stop button (2).
Hold the ignition key (1) directly to the key symbol (2) on the steering column.
Note:
Hold the ignition key without moving it.
The Check Control message "update of key data" appears.
A sounding of the acoustic signal two times and a disappearing of the triangle notice in the KOMBI signifies the
end of the transfer.
Note:
No acoustic signal suggests faults during the data transfer. The process must be repeated.
Data tapping in vehicles with no key slot (G Series):

Note:

2. Also press the start/stop button (2) three times within 4 seconds.
Hold the ignition key (1) directly to the key symbol (2) on the steering column within 10 seconds.
Note:
Hold the ignition key without moving it.
The Check Control message "update of key data" appears.
A sounding of the acoustic signal two times and a disappearing of the triangle notice in the KOMBI signifies the
end of the transfer.
Note:
No acoustic signal suggests faults during the data transfer. The process must be repeated.
00 02 14 (064)
Inflation pressure measurement in vehicles with tyre pressure display RDC (SA2VB)
Situation: The standard equipment of all new vehicles will in future cover a tyre pressure
display RDC (SA2VB) for each individual wheel. Sensors on all four wheels enable a
precise and individual monitoring of the tyre pressure. The respective current tyre
pressure is displayed on the control display or in the KOMBI, depending model and equipment. In the event of
a pressure deviation, the driver is alerted to a potential danger with an early warning signal.
In order to prevent false warning messages in customer use, Service must ensure that the tyre pressure is
correctly adjusted.
In the event of a tyre pressure loss of at least 20% or if pressure drops below the lower warning threshold
value, the warning signal in the vehicle is activated. The lower warning threshold level takes account of the
influencing factors and tolerances at a maximum of 1.8 bar.
The warning message can be affected by a range of influencing factors:
1. Low pressure difference between the setpoint value and the lower warning threshold value.
2. Temperature fluctuations during inflation pressure measurement/correction.
3. Tyre pressure losses when disconnecting the tyre inflator at the valve.
4. Pressure indicator tolerance on the tyre inflator.
Additional information on the tyre pressure display (RDC) can be found in the functional description "Tyre
pressure control".
Vehicles concerned:BMW, MINI and Rolls-Royce with SA2VB
Procedure: There are number of influencing factors that must be considered when measuring inflation
pressure in Service:
1. Avoid tyre pressure losses when disconnecting the tyre inflator at the valve.
=> In the event of tyre pressure loss, check the tyre pressure and adjust if required.
2. Observe the tolerance of the tyre inflator when measuring inflation pressure.
=> The indicated value of tyre pressure label must be increased by 0.1 bar to compensate the tolerance
in the tyre pressure device.
Attention!
When compensating the tolerance, the maximum pressure value indicated on the tyres must not be
exceeded.
Recommendation:
As described in the Owner's Handbook, customers must be made aware of the need to regularly check the air
pressure in the tyres and to reset the tyre pressure indicator.
00 29 18 (536)
Introduction of new service interval for ECE countries (RDE diesel fuel)
Situation: With cars enabled to meet modified emission limits, there can be increased dilution of the
engine oil.
ECE diesel vehicles will gradually receive a new standard service interval (SA8KB =>
25,000 km / 24 months) with qualification for RDE (Real Driving Emissions).
For vehicles with the modified service interval (25,000 km / 24 months), the combination of the scope of
maintenance work for the fuel filter changes.
The remaining scopes of maintenance work are unchanged in accordance with the previous combinations
(SA8KA).
Vehicles concerned:Note: The list of affected vehicles will be updated in accordance with the launch of
SA8KB.
Introduction date Vehicle affected Engine Transmission

04/2018 G02 (as of series introduction) no restriction
07/2018 G30 / G31 B47 Automatic transmission
G32 B47
08/2018 G01 B57
G05 (as of series introduction) B57
G15 (as of series introduction) B57
11/2018 G30 / G31 / G32 B57
G14 (as of series introduction) no restriction
G20 (as of series introduction) no restriction
12/2018 G07 (as of series introduction) no restriction
03/2019 F22 / F23 B47 Manual gearbox
F32 / F33 / F34 / F36 B47 Manual gearbox
F32 / F33 / F34 / F36 B57 no restriction
G11 / G12 B57 no restriction
G30 / G31 B47 Additionally for manual gearbox
04/2019 G01 Additionally B47 no restriction
07/2019 F39 / F48 B37 / B47 no restriction
F45 / F46 B37 / B47
F40 (as of series introduction) no restriction
G16 (as of series introduction)
G21 (as of series introduction)
F54 / F60
Procedure: For vehicles with the modified service interval (25,000 km / 24 months), the combination of
the scope of maintenance work for the fuel filter changes.
The remaining scopes of maintenance work are unchanged in accordance with the
previous combinations (SA8KA).
Fuel filter (diesel fuel)

with SA8KB (25,000 km / 24 months)
=> renew with each third engine oil change (approx. 75,000 km).
with SA8KA (30,000 km / 24 months)
=> renew with every 2nd engine oil change (approx. 60,000 km).
00 01 08 (483)
New ”Maintenance Records” service booklet and maintenance documentation
All models
Situation: At this time, a service booklet accompanies each vehicle as a means of providing the
customer with information about scope of maintenance and as maintenance
documentation, the record of the vehicle's maintenance history. The service booklets
differ in the description of the maintenance system, the maintenance overview and language. In all, there are
considerably more than 100 different service booklets.
The service booklet will be radically revised for all vehicles as of model year 2009 (production as of 08/08 or
09/08, as applicable). For the sake of simplification, customer information has been moved from the service
booklet to the owner's handbook for the vehicle. This, in turn, reduces the scope of the information in the
service booklet to the maintenance documentation, the record documenting the vehicle's maintenance
history. Symbols are now used, simplifying the use of the maintenance documentation and enabling the new
booklet ”Maintenance Records” to be used independently of natural languages.
In future, there will be only one Maintenance Records booklet used for all BMW models. Similarly, there will be
a single 'Maintenance Records for M Vehicles booklet for all M vehicles. The old-style service booklets will
remain available for ordering as spare parts for vehicles manufactured prior to 09/08. The changeover for MINI
vehicles will probably take place in 12/08.
Procedure: The procedure for documentation remains the same, but the boxes for the entries have
been changed.
1. Enter the Vehicle Identification Number (VIN): Page 3
2. Enter date of pre-delivery check in day/month/year form: Page 9.
3. Document maintenance records: Page 12ff.
- Enter maintenance item as
”X” for not checked
”Tick” for checked
It is not permissible to leave a box blank.
The meanings of the symbols are explained on Pages 6-8; they correspond as far as possible to the symbols
used in the vehicle.
- Odometer reading / date
Enter odometer reading in kilometres/miles
Enter date of maintenance in day/month/year form
- Confirm entries:
Confirm entries by company stamp and signature.
It is also possible to glue in certificates for accident repairs, for example, on Page 2.
00 05 06 (322)
Revised scope of maintenance work
M47TÜ1/2, M57, M57TÜ1
Situation: Replacing oil separator.
Vehicles concerned:
M47TÜ1/2 09/02 - 06/05 E46, E83, E87, E90
Exchange for dual cyclone as approved in ETK
M57 09/02‐(EOP) 12/03 E39, E46, E53

Exchange for fleece roll
M57TÜ1 09/02 - 06/05 E46, E53, E60, E61, E65, E83

Exchange for dual cyclone as approved in ETK
Procedure: Based on current quality inspections, the oil separator must be replaced as part of every
3rd engine oil change (charged separately).
00 17 01 (771)
Revised scope of maintenance work, MY 2002
E36/7/S54B32, E46, E46 M3, E39/M57, E53, R50
Situation: The following scope of repair work/changes apply to the current model year 2002.
Procedure:
1. These model variants are new:

E46/5 318td, 320td, M47TÜ:
Scope of maintenance same as E46/4 320d M47(TU => technical update)
E46 with N42 engines
Scope of maintenance same as E46/5 316ti N42
E53 X5 4.6is:
Scope of maintenance same as E53 X5 4.4i
R50 Mini One, Mini Cooper:
Scope of maintenance same as E46 316i M43 with the following exceptions:
Additions to pre-delivery check:
Remove spring blocker
Attachment of brief instructions to the operating lever on the steering column or the steering
wheel rim
Oil service:
First engine oil service after 16,000 km due to factory oil fill.All remaining oil changes as per
E46/5
Not applicable during oil service:
Brake pads: when changing rear: Check parking brake.
Addition to inspection I:
Change CVT automatic transmission fluid
Addition to inspection II:
Renew poly-V belt
2. The following work scopes have been revised:

E46 M3, E46/7 M Coupé, M Roadster with S54B32
Additions to pre-delivery check:
Activate engine speed limitation
Note:
To prevent unacceptably high engine wear, data statuses restrict the maximum engine speed
to 5500 rpm from the factory until delivery of the vehicles to the dealers.
This engine speed limitation is rescinded by the dealer during the pre-delivery check using the
diagnosis and information system tester.
On DIS CD28 onwards, the engine speed limitation is disabled on the tester interface under:=>
”Control unit functions” => ”Complete vehicle” => ”Drive” => ”Digitalengine electronics” => ”Confirm
pre-delivery check”.
3. Notes:
Issuing of Inspection Sheets on the TIS CD:
E46/5 316ti with N42 - 10/01E46/5 325ti with M54 - 10/01
E53 X5 3.0d with M57 - 10/01
E36/7 M Roadster, M Coupé S54B32 - 10/01
Issuing of flat rate units on the Commercial Service Data CD:
E46/5 316ti with N42 - 06.01
E46/5 325ti with M54 - 06.01
E53 X5 3.0d with M57 - 04.01
E36/7 M Roadster, M Coupé S54B32 - 02.01
4. General:
Ensure that the Inspection Sheet is always enclosed with the numbered work order for every piece
of maintenance work. By signing this document, the responsible party confirms that all maintenance
work has been properly carried out. The Inspection Sheet is part of the vehicle records. It acts as
proof of performance of the individual items of repair work in the event of complaints regarding the
numbered work order and protects the performing workshop against any unjustified workshop,
warranty or other regressive claims.
It is absolutely essential that all customer service, parts sales and sales staff who have contact
with customers are informed of the changes to the maintenance system.
00 02 10 (661)
Service intervals for countries with low fuel grade (SA988/SA8KE, SA8KM, SA984,
SA8KK, SA8KL, SA8KH, SA8KP)
BMW and MINI
Situation: To ensure mobility, various service intervals (poor-fuel intervals) are targeted ex-works
(depending on country requirements).
Vehicles concerned:BMW and MINI
Measure: Note:
In countries with higher levels of dust, the air cleaner should be checked for contamination
at every engine oil service. If there is significant contamination, the change interval must
be accordingly reduced.
Oil service interval SA988 (petrol):
Carry out engine oil change approx. every 12,000 km (24 months).
Change intervals that are linked with the engine oil service:
For vehicles built up to 09/2008:
Replace the microfilter at every 2nd engine oil change
Replace the air filter at every 6th engine oil change
Replace the spark plugs at every 6th engine oil change
For vehicles built from 03/2009:
For M vehicles (E6x, E8x and E9x):
Replace the final drive oil at every 6th engine oil change
Replace manual gearbox oil or SMG transmission oil (clean SMG transmission oil filter) at every 6th
engine oil change
Note: not for twin-clutch gearbox!
Carry out vehicle check after 48 months, at the latest.
Oil service interval SA8KE:
Only for M-vehicles (F1x):
Only in hybrid cars (F01H, F02H, F10H and F30H)
Replace automatic transmission fluid at every 5th engine oil change.
Carry out vehicle check at each fifth engine oil service or after 48 months, at the latest.
Oil service interval SA8KM:
Only for F15/F16 with engine N63: Replace air cleaner during every engine oil change
Only for I12 and MINI John Cooper Works (R55, R56, R57, R58, R59, R60, R61):
Replace spark plugs at every 2nd engine oil change
Renew fuel filter (diesel) with every 5th engine oil change
M vehicles only:
Renew automatic transmission fluid at every 5th engine oil change
I12 only:
Check bolting of door hinge at every 2nd engine oil change
Renew gas pressure spring of front door at every 4th engine oil change
Build date up to and including version 02/2015: Renew drive belt at every 5th engine oil change
Carry out vehicle check at each fifth engine oil service or after 48 months, at the latest.
Oil service interval SA984 (diesel fuel):
Replace the fuel filter at every 6th engine oil change
Replace the fuel filter at every 4th engine oil change
Oil service interval SA984 (petrol):
Replace microfilter at every engine oil change
Replace the spark plugs at every 3rd engine oil change
Replace the air filter at every 3rd engine oil change
Oil service interval SA8KK:
Only for F15/F16 with engine N63: Replace air cleaner during every engine oil change
Only for I12 and MINI John Cooper Works (R55, R56, R57, R58, R59, R60, R61):
Replace spark plugs at every 2nd engine oil change
M vehicles only:
I12 only:
Check bolting of door hinge at every engine oil change
Renew gas pressure spring of front door at every 2nd engine oil change
Build date up to and including version 02/2015: Renew drive belt at every 4th engine oil change
Carry out vehicle check at each fourth engine oil service or after 36 months, at the latest.
Oil service interval SA8KL:
For countries with higher levels of dust: Check the air cleaner for contamination and reduce the change
interval if applicable!
M vehicles only:
Carry out vehicle check at each fourth engine oil service or after 48 months, at the latest.
Oil service interval SA8KH:
Replace the air filter at every 3rd engine oil change
Renew fuel filter (diesel) with every 3rd engine oil change
M vehicles only:
Replace automatic transmission fluid at every 3rd engine oil change.
Carry out vehicle check at each third engine oil service or after 36 months, at the latest.
Oil service interval SA8KP (petrol):
Carry out vehicle check at each 7th engine oil service or after 48 months, at the latest.
Procedure: The change intervals that are due at the Service visit and the corresponding links for
microfilters, air filters, spark plugs, fuel filters and the vehicle check are displayed correctly
via ISPA depending on the service interval coding.
Country-specific deviations of the change intervals are possible depending on market requirements. This is
manually controlled in each market.
The maintenance work must be carried out as shown in the Commercial Service Data and ISTA.
00 01 07 (343)
Service Sheets - Condition-based Service/Pre-delivery Check (ISTA, ISPA, Commercial
Service Data)
BMW, MINI
Situation: The information "Condition-based Service - Service Sheets" is generally available via
ISPA and Commercial Service Data for Condition-based Service and service interval
indicator vehicles, which must be printed within the framework of the order preparation.
ISPA offers the advantage of only showing the due scopes of service work on a vehicle-specific basis.
Technical information is available in ISTA.
Procedure: Service sheets:
The service sheet is printed out with ISPA or Commercial Service Data in the course of the service
consultation.
a. ISPA: Read in ignition key -> Scopes of service work are selected/Select -> Menu Job order basis -
> Print service sheet
b. ISPA: Open key data application -> Menu Job order basis -> Print manual service sheet -> Vehicle
identification (17-character vehicle identification number) -> Print service sheet
c. KSD: Vehicle identification -> Maintenance (Inspection Sheets) -> Condition-based Service
Note: Country-specific deviations of the intervals shown on the Inspection Sheet are possible.
Observe maintenance requirement in ISPA!
The engine oil top-up quantity can alternatively be determined via ISTA, EPC or KSD (Commercial Service
Data).
a. ISTA. Vehicle identification -> Product structure -> Technical data -> 11 Engine -> 11 40 Oil supply /
11 00 Overview of Technical Data
b. EPC: Vehicle identification (vehicle identification number) -> Additional information -> Capacities
c. KSD: Vehicle identification (vehicle identification number) -> Packages -> Maintenance -> Service
engine oil
or
KSD: Vehicle identification (vehicle identification number) -> Maintenance (Inspection Sheets) ->
Condition-based Service -> Service engine oil
Additional information on the scopes of maintenance work is available in ISTA:

Product structure -> Repair instructions -> 0 Maintenance and general information
Pre-delivery check:
The pre-delivery check is printed out with ISPA, ISTA or Commercial Service Data in the course of the
service consultation.
a. ISPA: Read in ignition key with due pre-delivery check -> Menu Job order basis -> Print pre-delivery
check
b. ISTA: Vehicle identification -> Product structure -> Repair instructions -> 0 Maintenance and general
information -> Pre-delivery check
c. KSD: Vehicle identification -> Maintenance (Inspection Sheets) -> Pre-delivery check
Further information:
ISTA: Vehicle identification -> Product structure -> Repair instructions -> 0 Maintenance and general
information
00 13 11 (697)
Standard work scope - expansion of work scope (with slide/tilt sunroof and panorama
glass roof)
Check guide rails and water drain channels in slide/tilt sunroof or panorama
glass roof for dirt contamination
Situation: During a regular workshop visit in the course of maintenance (standard service scope),
the guide rails and water drain channels in slide/tilt sunroof or panorama glass roof must
be checked for dirt contamination.
Vehicles concerned:All BMW, MINI and Rolls-Royce with slide/tilt sunroof and panorama glass roof.
Procedure:
Glass slide/tilt sunroof panel fully open.

Check guide rail (1) and water drain channel (2) on left and right for dirt contamination. In the case of dirt
contamination, guide rail (1) and water drain channel (2) on left and right must be cleaned against separate
charge.
Check the spare wheel well and luggage compartment side boxes for moisture. If moisture is found, note the
procedure of the respective vehicle-specific Product and Measures Management Aftersales (PuMA) measure.
00 05 09 (608)
Emergency Services (BMW/MINI) from issue September 2009
new OSS address
Situation: An update of the Emergency Services is no longer available on the
Aftersales Assistance Portal (ASAP). A current version of the Emergency Services now
only at the online Service System for BMW Service and MINI Service (OSS) at the
following Internet address:
https://oss.bmw.de/index.jsp
Affected vehicles:BMW and MINI

61 03 98 (387)
Battery recharging intervals for booth vehicles, battery charging calendars and
battery tags (12-V battery, high-voltage battery unit)
All models
Situation: Due to the self-discharging of the vehicle battery (12 V battery, high-voltage battery unit)
and vehicle standby current (if the vehicle battery was not disconnected from the vehicle
electrical system), the vehicle battery is discharged slowly, but continuously.
If the vehicle battery is not recharged for an extended period of time, it will be damaged. This will result in a
premature battery failure.
Measure: To maintain the quality of the vehicle battery in standing vehicles, it is necessary to
recharge this vehicle battery regularly.
Procedure: Recharging intervals:
12V battery
All vehicles:
12-V battery connected to the vehicle electrical system: 6 weeks
All vehicles without BMW i and Plug-in Hybrid (PHEV):
Continuous disconnection of the 12-V battery from the vehicle electrical system by removal of the
ground cable to the 12 V battery or by switching off of the fitted battery master switch, if installed:
12 weeks
High-voltage battery units:

All vehicles: 6 weeks
Plug-in-hybrid (PHEV): as required
The recharging intervals follow the battery charging calendar.

Recharge when the colour of the calendar week on the battery calendar matches the colour of the battery tag.
Battery tags are located on all new vehicles' interior mirror.
N.B.:
1. Since different systems are used by distribution channels for documentation, it is not always clear
whether the vehicle battery was actually recharged during the week that is indicated. Therefore all
recharge procedures must also be documented on the battery tag on the interior mirror (write date of
recharge with a smudge-proof pen and confirm that the work has been carried out with your
signature next to the date). The battery tag remains in the vehicle until the vehicle is handed over to
the customer and is then filed with the vehicle records.
2. Dealers who store the vehicles externally (e.g. at freight forwarding businesses) are responsible for
making sure that the vehicle batteries for these vehicles are recharged according to the battery
charging calendar.
3. For vehicles in show rooms, the battery tags must be placed in the glove box. In the case of an
increased draw on the charge (e.g. when doors are opened, the radio is turned on, electrical seat
adjustment is operated), much shorter recharging intervals are required on these vehicles (e.g. every
night) so that a total battery discharge is reliably avoided. It is however better to provide for charge
compensation by means of a permanent support charge in the showroom.
"Trickle charger" SI 02 03 05 (205)
Parts: Battery log form (not just for USA)

{Battery Log Form} (for USA only)
Designation Part number Quantity
Battery tag, coloured
whisky 01 89 9 781 424 as needed
sun yellow 01 89 9 781 425 as needed
emerald 01 89 9 781 426 as needed
california blue 01 89 9 781 427 as needed
brick red 01 89 9 781 428 as needed
Grey 01 89 9 781 429 as needed
61 03 98 (387)
All models
12V battery
All vehicles:
12 weeks


N.B.:
charging calendar.

00 02 06 (296)
Drawbar load sign omitted
All with options 235 and 3AC
Situation: There have been new vehicle documents since 2005-10-01.

Beginning with this production date, vehicles no longer need to be equipped with
the trailer hitch drawbar load sign.
Corresponding information on the options is provided in the vehicle documents.
The regulation pertains to all series.
41 02 09 (521)
New repair methods ”Gluing / Riveting” on steel bodies
BMW/MINI
Situation: Advance technical developments in the field of adhesives and equipment technology
have made modified repair methods possible. This procedure has been tested and
approved following exhaustive endurance runs and corrosion tests in the Development
division.
Similar to the procedure for the tail panel on the F01/F02, the repair methods "welding/soldering" will change to
"gluing/riveting" on various outer skin and structural components of steel bodies from the launch of the E89
and R57. This procedure has already been introduced for repair work on the reduced-weight aluminium front
end (GRAV) of the E60.
The repairs can be performed by all workshops that have participated in a GRAV or the current bonding and
riveting training, in combination with the training video.
Another positive point of this method is the significantly improved corrosion protection resulting from the wide-
area bonding of the spare part coating (KTL).
Procedure: Essentially, the following components are affected:
Rear side wall
Tail panel
Boot floor
Roof outer skin
engine carrier
support carrier
Model series affected:
MINI (R55, R56, R57)
BMW 1 Series (as of E8x)
3 Series (as of E9x)
5 Series (as of E60)
X1 (E84)
X5 (E70)
X6 (E71)
Z4 (E89)
7 Series (as of F01)
And all future series.
Necessary workshop equipment:
Punch riveting tool
Cartridge gun for body glue
Universal collet (for roof ducts)
Infrared lamp
For more information on the required tools, see Service Information.
Parts required:
The new parts and consumables required for the respective scope of repair work are listed in the Electronic
Parts Catalogue (EPC).
In addition, vehicle-specific service repair packages are also offered. Here, the vehicle identification number is
to be entered in KSD2, the corresponding "Packages" button selected and the required job item selected in
main group 41.
Repair instructions:
The repair instructions have been revised to take account of the new repair method:
To differentiate the individual repair methods, the repair stage is inserted in the repair instructions.
Repair stage 1: All repairs that only provide for replacement of screwed/bolted components and
planishing operations.
Repair stage 2: Repairs that are carried out by bonding and riveting without the use of a straightening
bench.
Repair stage 3: Repairs that are carried out by bonding and riveting with the use of a straightening bench
or welding.
Training video for bonding and riveting:
The new methods, for example "punch riveting", have been described on a training video that will be distributed
to National Sales Companies.
Please make sure the training video is made available to the staff who will be performing this work and, if you
do not perform body repair in your own workshop, to the staff of your specialist body workshop.
The BMW paint brochure can be ordered via the usual parts-related channel under the BMW parts number
01 69 0 037 577.
Time allowances:
Time allowances (flat rates) have been revised to take account of the new repair methods and shall apply
retrospectively.
31 01 12 (833)
Visible corrosion on vehicle add-on parts
Situation: Since the market introduction of the E65/66 the engine compartment and underbody
preservation has successively been dropped from all series for environmental protection
reasons. This may result in visible corrosion of machined surfaces such as, for example,
on chassis/suspension components, machined screwing/bolting points, screw connections, or on surfaces
such as, for example, the joints and drive shafts!
To prevent or re-treat this surface corrosion, the dealer organisation should use the corrosion protection with
BMW part number 83 19 2 317 997.
Vehicles concerned:All BMW, MINI series
Procedure: Apply a thin coating of corrosion inhibitor (using only a brush) to the affected areas.
Warning!
Risk of fire!
Do not apply any corrosion inhibitor to the engine or the exhaust system!
00 12 07 (381)
Arguments pertaining to engine oil consumption
BMW, MINI
Subject matter
Customers are often unsure when it comes to the subject of engine oil consumption. Is an engine allowed to
consume oil? What are the most important causes of engine oil consumption?
The following explanations are intended to provide an aid to argumentation. They are aimed at all dealership
staff who have contact with customers.
Functions of engine oil
Engine oil is one of the most important operating fluids in a combustion engine. The engine cannot work
properly without engine oil. The main functions of engine oil are:
Lubrication
Cooling
Prevention of corrosion and sedimentation
Lubrication
The lubricating film or the engine oil is exposed to a wide range of demands. The viscosity of the engine oil
should not be too high at low temperatures so as to ensure optimum lubrication already at cold engine
temperatures (e.g. cold starting). On the other hand, the engine oil should not be too thin-bodied at high
temperatures as this can break down the lubricating film and nullify the lubricating effect entirely.
The most important function of the engine oil is to minimise friction between metal surfaces. This function is
effected by a lubricating film which builds up during operation between the surfaces of the moving engine
components. The thin oil film reduces friction significantly, which translates into lower wear and lower heat
generation. As well as preventing piston seizures and bearing damage, it extends the service life of all the
relevant engine components and reduces fuel consumption.
Another function of the oil film is to seal the combustion chamber against the crankcase via the piston rings.
, cooling
The pistons already reach their operating temperature shortly after the engine is started. It can take a few
minutes, depending on the ambient temperature, the engine design and the driving style adopted, for the
engine block and thus the cylinder walls to reach their operating temperature. The engine needs a fully
functioning cooling system to stop it from exceeding the operating temperature. Aside from the two classic
cooling components - air and coolant - engine oil is often underestimated or even forgotten as a crucial cooling
component. The engine oil is responsible for a significant degree of cooling inside the engine. Specifically to
cool the piston crowns, virtually all BMW engines have oil spray nozzles which moisten the piston crowns with
engine oil.
Prevention of corrosion and sedimentation
Last but not least, it is the job of the engine oil to protect the engine against corrosion and sedimentation.
Aggressive combustion residues are neutralised by the lubricating oil and appropriate additives. The remaining
combustion residues are carried by the oil circuit to the oil filter, where they are filtered, or settle in the oil
sump.
Engine oil consumption
Engine oil consumption is dictated above all by the structural design of the individual assemblies or systems.
Every combustion engine has a system-dictated consumption of lubricating oil. Decisive causes of engine oil
consumption are:
Pistons with piston rings
Valve stem seals
Crankcase ventilation
The surface topography used of cylinder barrel and piston ring is the primary variable which directly influences
engine oil consumption, since the piston rings do not constitute a perfect seal, but instead act as a metering
unit. With regard to design, there is a conflict of interests between engine oil consumption and friction loss. The
letter has a direct effect on power and fuel consumption. In each piston stroke tiny quantities of engine oil are
left on the cylinder walls and this oil is essential for lubricating the piston rings and the piston skirt (see above,
lubricating film). During the piston downstroke the engine oil deposited on the cylinder wall takes part in the
combustion close to the wall and is discharged with the combustion gases. The higher the engine speed, the
greater the effect, since more combustion cycles per unit of time take place. For this reason, engines with a
high rpm concept (BMW M engines) tend to have a higher engine oil consumption than other BMW engines.
The same applies to the lubricating film on the valve stems.
Note:
For BMW spark-ignition and diesel engines, the maximum permissible engine oil consumption is
0.7 l/1000 km.
Because of their increased power output and torque, M engines have a maximum permissible oil
consumption of 1.5 l/1000 km.
The measurable result of an engine oil consumption is overridden by the quality of the fuel used and of the
driving profile. If, for example, in winter a lot of short distances are driven (= high fuel entry since the
vaporisation temperature is for the most part only briefly achieved) and then a longer distance is driven (fuel
can now vaporise), a significant drop in the engine oil level is encountered on this trip. This does not constitute
engine oil consumption, but instead merely a different engine oil level on account of the fuel content in the
engine oil. Customer complaints can often be put down to this fact. The situation can arise where the engine oil
level drops over a few 100 km by around 1 litre. Added to this is some engines is a degree of uncertainty of up
to 0.3 litres by the relevant measuring system (oil dipstick/QLT).
Even the oil mist particles entrained via the crankcase ventilation (separation efficiency technically never
100 %) take part with the intake air in the combustion process. The design is particularly problematic here. On
the one hand, engine oil should be separated as fully as possible; on the other hand; crankcase pressure
requirements must be satisfied. Moreover, conventional separation systems function to optimum effect only
with a specific gas flow rate; the separation effect decreases with lower or higher gas quantities.
Summary
Every internal combustion engine has a technically necessary engine oil consumption. The level of engine oil
consumption is clearly influenced by the driveability and by the fuel used.
Oil consumption measurement
The level of engine oil consumption that may arise with a particular engine can be determined by the customer
only from the amount of engine oil he or she tops up with. As soon as the engine oil level falls below the
maximum mark on the dipstick, many customers top up the engine oil without paying attention to a number of
basic rules, such as the vehicle must be standing on level ground, a certain period of time must be left to allow
the oil to flow back to the sump. In such cases, the available container sizes (e.g. 1-litre can) make it easy to
top up above the maximum mark. Excess engine oil can cause engine damage and is consumed more quickly
due to the effects of splash.
For this reason, it is advisable to let the engine oil level drop as far as the minimum mark and only then to add
the required volume of engine oil. The difference between the two marks is approximately 1.0 to 1.5 litres.
available (see SBS 11 07 96 138, Enclosure 12).
00 26 11 (731)
Brake fluid - Operating Fluids Specification
Situation: To provide permanent surface protection in the brake system, only low viscosity DOT4
brake fluids that have been approved by BMW may be used.
Vehicles concerned:All BMW, MINI and Rolls-Royce.
Procedure: The low viscosity DOT4 brake fluids currently approved by BMW can be viewed in the
current ISTA version (operating materials - main group 34).
00 30 11 (735)
All MINI
All Rolls-Royce
00 03 10 (663)
Annual vehicle inspection in compliance with labour protection and accident
prevention according to Operating Safety Ordinance BGV D 29 and BBG 916
Germany only
Situation: In order to comply with European and German legislation on labour protection and the
occupational safety of employees, it is necessary to observe the guidelines and
directives drawn up by the German Social Accident Insurance Institution within the
framework of accident prevention regulations:
1. German Social Accident Insurance Institution ordinance BGV D 29 “Accident prevention regulation -
vehicles”
Accordingly an employer must have all vehicles which are used for commercial purposes by himself or by
employees, regardless of whether they are officially registered or not, inspected to ascertained their
operationally safe condition at least once per year.
Excluded from this requirement are private vehicles used for business or social purposes and test vehicles.
2. German Social Accident Insurance Institution principle BGG 916 “Inspection of vehicles by experts”
This inspection - as contemplated by the accident prevention regulations - can be conducted by an officially
recognised specialist or inspector within the framework of a §29 inspection or also by an expert.
Experts as contemplated by this ordinance are persons who, as a result of their specialist training and
experience, have knowledge in the field of automotive engineering and of the relevant labour protection and
accident prevention regulations. These include in the automotive trade all skilled workers and workshop
foremen.
The scope of inspection for “Operating Safety” must cover all matters pertaining to roadworthiness and
occupational safety.
The inspection in accordance with BGV D 29 in conjunction with BGG 916 focuses on:
Equipment required by law – warning triangle, first-aid kit
High-visibility jacket
Documents to be carried – car registration papers, Owner's Handbook, acceptance report, etc.
Type approval of non-standard modifications, fittings, etc.
View/windows – heating – mirrors – electrical equipment
Moving add-on parts and body components
Securing of loads – load area nets, lashing points, roof boxes
Trailer tow hitch
Grab handles, head restraints, seats, seat belts
Vehicle condition check:
Passenger compartment, general condition
Rims and tyres, type approval, condition, damage
Lights, auxiliary headlamps
Vehicle condition - exterior, underbody, loose parts
Vehicle chequebook
The inspection is to be documented in the form of an inspection record, which is to be kept until the next
inspection due.
Vehicles concerned:All BMW Group vehicles (cars and motorcycles), i.e. BMW, MINI, Rolls-Royce and
BMW Motorrad and vehicles of other manufacturers in the company in question.
Procedure: If the inspection is not conducted on the basis of a §29 inspection, it can be conducted for
passenger vehicles (vehicle category M1 up to 3.5 t permitted vehicle weight) by working
through the inspection lists of the vehicle manufacturers provided that all the matters
relevant to occupational safety and roadworthiness are taken into consideration. In practice the “large”
inspection lists contain all the safety-relevant test points.
BMW vehicles with service interval indicators are covered in each case by the current Inspection Sheet II (see
example in Appendix 2). These are all BMW vehicles up to and including E46 as well as E83 and E85 and MINI
R50, R52 and R53.
Vehicles with CBS (Condition Based Service) are covered in each case by the current “Condition Based
Service” list (see example in Appendix 3). These are all BMW vehicles from E65 and higher (but not including
E83 and E85) as well as MINI from R56 and higher and Rolls-Royce.
Note: Changing service fluids, filters and spark plugs is not necessary in this respect and is dependent solely
on the specified BMW service intervals.
In addition to the test specifications in the inspection lists it is also necessary to check for the presence of
first-aid kits and high-visibility jackets. In the case of vehicles used for commercial purposes which in
accordance with EC Regulation 3821/85/EC must be fitted with a digital recording device (“tachograph”) in
order to record driving times/rest periods and working hours, this requirement also covers checking for the
presence and correct function of the recording device.
An inspection in accordance with the ordinance at hand is only then positively concluded if there no
defects/deficiencies.
When the inspection has been completed an inspection record as shown in the appendix complete with
details of the object inspected, e.g. vehicle identification number, and the inspection date must be drawn up
and initialled by the person inspecting. It is useful for this record also to be initialled by the relevant employer
or his authorised person or representative.
A printed specimen of the inspection record is attached as Appendix 1 to this Service Information bulletin.
Forms for the inspection results can be purchased from Carl Heymanns Verlag under the title “Prüfbefund über
die regelmäßige Prüfung von Fahrzeugen durch den Sachkundigen”.
For the sake of completeness the inspection sheet applicable to the vehicle to be inspected or a copy of the
§29 inspection report should be attached to the inspection record.
An inspection badge as shown in the graphic can be attached to the vehicle on a voluntary basis; this is
usually done only in the case of technical tools/work equipment or if the same vehicle is used for commercial
purposes over a period of several years.
This badge can be obtained from for example the relevant German Social Accident Insurance Institution or the
Internet: www.prüfplakette.com.
Notes: This vehicle inspection prescribed for occupational safety law reasons does not for
vehicles with number plates replace the general inspections at the corresponding
inspection intervals prescribed in accordance with the German road traffic legislation §29
StVZO.
It is also recommended to contact the German Social Accident Insurance Institution for the metalworking
industry (BGM) or the vehicle operating trades (BGF) for information on the current ordinances and principles.
These vehicle inspections can also be offered as a service to external customers using vehicles for
commercial purposes.
Reimbursement:No BMW flat rate units or defect codes are specified for this inspection since this scope
cannot be invoiced through the warranty channel.
00 04 06 (268)
Changed emissions test indicator
BMW Condition Based Service
Situation: The emissions test indicator in the CBS can be activated and deactivated. The default
encoding for the emissions test indicator depends on the market concerned.
Procedure:
Start diagnosis system
Perform vehicle identification
In diagnosis, change to fault pattern analysis and activate function selection
Select service functions
Maintenance
CBS vehicle data correction
Select testing schedule
Start CBS vehicle data correction SCBS_6004
Select CBS correction operations (point [2])
Select general inspection (point [3]) or emissions test (point [4])
Activate or deactivate indicator
If activating, select and enter new date
00 18 12 (864)
General and legal information on performing the periodic exhaust-gas (emissions) test
in EU countries
BMW vehicles built between 1968 and 03/2012, MINI as from R50 and
Rolls Royce as from RR01
Situation: I. In view of the EU updates of the regulations* covering the vehicle inspection at regular
intervals, in which the exhaust-gas test forms part of the inspection, * = last version:
2010/48/EC of 05.07.2010
and the proportionate adoption of EU-valid minimum emissions test inspection specifications by the
German Ministry of Transport for the periodic motor vehicle inspection (§29_StVZO) as from mid-2012,
and the easier comprehensibility and improved overview, e.g. division into EU specifications and
specifications only applicable to Germany
the BMW Service Information bulletins pertaining to the exhaust-gas test which have been in circulation since
1993 are updated, restructured and divided into:
1. General and legal emissions test information
2. Emissions test instructions for BMW Group vehicles with petrol engines
3. Emissions test instructions for BMW Group vehicles with diesel engines
4. Emissions test instructions for BMW Group vehicles with alternative drives
II. Within the framework of this restructuring and updating the General and legal information on the exhaust-
gas test will be set out in this Service Information bulletin.
1. EU matters (proportionately also applicable to some other ECE markets):
An exhaust emissions test at regular intervals was introduced from March 1998 at the latest in all EU countries
for all passenger cars, trucks and buses. The exhaust emissions test forms part of the overall technical motor
vehicle inspection. The basis for this is EU Directive 96/96/EC of 20.12.1996 together with its exhaust-related
updates 2001/9/EC and 2003/27/EC. The currently valid version is EU Directive 2010/48/EC of July 2010. The
inspection contents specified in the above-mentioned directives are minimum scopes which however,
depending on the EU state and particular reasons, e.g. high air pollution, large proportion of traffic, may be
nationally extended or intensified.
The inspection intervals vary, depending on the country, for privately used vehicles between 2 and 4 years for
the first inspection, and then repeated every 2 years. An annual interval applies to all commercially used hire
vehicles and passenger vehicles as well as to goods vehicles starting at 3.5 to in weight.
With regard to the inspection contents, a distinction is made between the type of drive:
all vehicles with engines with externally supplied ignition or petrol engines from 1968
all diesel-engine vehicles from 1980
For vehicles with alternative drives, e.g. hybrid systems, the vehicle manufacturer can, in line with the above-
mentioned 2 main groups and further to approval by the relevant national authorities, draw up type-specific
inspection specifications.
The EU and German exhaust emissions directives also contain, in addition to the scopes of inspection and
inspection procedures and the maximum permitted exhaust gas limit values, further specifications for the test
equipment (type approval, calibration) and the test environment such as e.g. for authorised inspectors,
equipment at the inspection site, etc.
2. Germany:
In Germany the special exhaust emissions test (“Abgas-Sonder-Untersuchung” - ASU) had already been
introduced on 01.04.1985 for passenger cars with petrol engines without closed-loop-controlled exhaust gas
aftertreatment systems, i.e. vehicles as from model year 1968.
From 01.12.1993 this periodic exhaust emissions test was extended under the name “Abgasuntersuchung”
(AU) (exhaust emissions test) to all passenger cars, i.e. also petrol vehicles with closed-loop-controlled
exhaust gas reduction systems (“U-Kat” or “G-Kat”) and all vehicles with diesel engines (passenger cars,
commercial vehicles and buses). From 01.04.2006 motorcycles as from model year 1980 were also
incorporated into the exhaust emissions test.
The statutory basis for this is provided by §29 and §47a and b of the German road traffic licensing regulations
(StVZO). From 01.04.2006 the hitherto separate exhaust emissions test became an integral part of the
technical motor vehicle inspection (§29), but may also continue to be carried out as a separate element by
recognised workshops.
Vehicles concerned:BMW vehicles: Petrol engine as from model year 1968; with diesel fuel as from MY
1983
MINI as from R50 and Rolls-Royce as from RR01
Procedure: 1. In the performance of the exhaust emissions test required by law, which constitutes an
sovereign act, the EU- and the country-specific administrative regulations must be
observed.
2. The technical details for the scope of inspection and type-specific particulars are to be obtained from the
Service Information bulletins listed below:
Emissions test instructions for BMW Group vehicles with petrol engines
Emissions test instructions for BMW Group vehicles with diesel engines
Emissions test instructions for BMW Group vehicles with alternative drives
3. Furthermore, primarily the manufacturer- and type-specific specified values, or if these are not available, the
statutory maximum limit values must be applied to the exhaust emissions test. These specified values, which
in part also contain setting instructions, are set out specifically for each type in the collection of BMW
emissions test nominal values.
Notes:
These emissions test nominal values are called up, depending on the user, via the Intranet or Extranet of the
BMW Aftersales Portal or for “third-party users”, via the Internet from the BMW web portal Technical Parts
Information System: “ASAP”, module - emissions test nominal values, at the web addresses:
http://www.parts.bmwgroup.com
or
http://www.aftersales.bmwgroup
These emissions test nominal values are for the most part - also in the course of the next due maintenance
on the BMW emission testers - loaded by the BMW-approved equipment manufacturers into the test
equipment memories.
Moreover, these data can also be obtained from the data catalogues of the open-market repair data
publishers (e.g. DAT, Eurotax, Autodata, etc.) once their publications have been updated.
The current database contains the nominal data for all vehicles of the BMW Group as well as MINI and
Rolls-Royce, i.e. produced between 1968 and 03-2012. Updates are usually issued in April and October
every year.
Remarks:
If you find that vehicles are either not listed in this database, or that a listing is incomplete or faulty, you are
advised to:
copy the reply sheet attached in Enclosure 1 of this Service Information bulletin,
get the testing personnel to complete/correct it
if necessary, send together with a copy of the vehicle's official registration papers or of the printout of the
nominal values to BMW AG Central Service - Repair Information, Dept. UA-72 by fax (no.: +49 89 382 4 17
88) or by e-mail to the address AU-Soll-Daten@bmw.de.
We will then amend or correct accordingly in the next update.
4. Officially specified test categories:

EU-wide and covering all engine designs:
Vehicle identification (number/license plate, km reading/mileage and vehicle identification number)
Visual inspection of all exhaust-relevant components for existence, absence of change and damage; on
vehicles with exhaust on-board diagnosis (EOBD): check of exhaust-relevant fault entries
Setting checks (idle speed and increased idle speed, if necessary ignition; diesel fuel: maximum speed)
Effective check by means of exhaust tailpipe measurement on:
Petrol engines:
without catalytic converter: CO at idle;
with closed-loop-controlled catalytic converter: CO, lambda
Diesel engines:
Exhaust gas opacity when revving the engine from idle up to maximum speed (no load)
Documentation of the test results and their evaluation (not OK or OK)
5. There are also regulations for type approval and regular calibration of emission testers. A wide range of
emission testers is tested and recommended by BMW in the interests of complying with its own service
conditions (integration in BMW workshop network, flat rate units, adaptation to BMW vehicles, etc.) and
published in the Workshop Equipment and Planning Catalogue (WEP).
Fig.: Examples of BMW-recommended emission testers.
6. Additional legal requirements in Germany:

The exhaust emissions test must be carried out with PC-based “operator prompting” installed in the
emission testers. This signifies a legally required test sequence and the associated automatic recording of the
test components. This is intended to eliminate the risk of tampering to the greatest possible extent.
For the purpose of certification the testing personnel must attend an initial training course and then a refresher
training course every 3 years.
Workshops that carry out the exhaust emissions test must be certified by the state authorities or on behalf of
them by the automotive trade guide with regard to the safety, suitability and completeness of the emissions
test equipment.
Since 2006 it has been required for the emissions test results, equipment maintenance and training courses to
be centrally recorded within the framework of a quality system.
7. General – covering all engine designs

Exhaust emissions test on vehicles with automatic transmissions
Vehicles with automatic transmissions may suffer failure of their multidisc clutches during exhaust emissions
test if the test steps take up too much time at higher engine speeds.
This concerns in diesel engines primarily the checking of the “maximum speed at no load” if it takes longer than
1.5 seconds and in petrol-engine vehicles with oxygen sensor emissions control (closed-loop-controlled
catalytic converter) if the conditioning phase of 3 minutes is applied at n => 3000 rpm.
This damage is caused by the high pressure in the hydraulic fluid circuit at engine speeds above approx. 2500
rpm, which results in a pressurisation of the clutch discs by way of leaks due to operation or wear. The linings
of these clutches are subject to increased wear with the selector lever in position “P” or “N” and the output
shaft or rear wheels stationary.
Effect: Primarily in the ZF type 4HP22 automatic transmission under the currently specified test conditions the
disc set of the “A” clutch may be detrimentally affected to such an extent that forward travel is no longer
possible after the exhaust emissions test has been completed.
Measure: With the vehicle stopped (selector lever in position “P”) and with the ZF 4HP22 automatic
transmission the following operating points (engine speed/time) must not be exceeded:
nengine = 2500 rpm --> max. 15 minutes
nengine = 3000 rpm --> max. 60 seconds
nengine = 5000 rpm --> max. 1.2 seconds
In the case of other automatic transmissions, the dwell time at higher engine speeds
( > 3000 rpm) must be limited to the absolutely necessary level.
00 14 03 (047)
Master document for exhaust emission inspection (AU) target data
All model series
Situation: The constantly increasing range of different engines has now grown to a degree that
makes it logical to allow data relevant to exhaust emissions to be called up concisely from
a single document.
Procedure: Call up publications containing data relevant to exhaust emissions via the following
hotspots:
1. Classification in exhaust emission standard Euro-II
E36 with M41 engine
2. Lambda control circuit check as part of exhaust emission inspection
E39/M5 Model year 99
3. Data relating to communication problems as part of exhaust emission inspection
E36, E53 from 01.01.1999
4. Exhaust emission inspection, substitute procedure for lambda control circuit check
E36 up to E53 since 01.06.1999
5. Information on exhaust emission target data of following model series
3 Series 5 Series 7 Series 8 Series M Series

E3 E34 E32 E31 R50 (MINI)
E30 E39 E38 E52 (Z8) R53 (MINI)
E36 E53 (X5) E65
E46 E60 E66
E67
E83 (X3)
Z1
Z3 (E36/7)
Z4 (E85)
6. Supplement for target exhaust emission data from 04/2007 to 03/2009 Test procedure for lean-mix petrol
engines. Amended test procedure and flat rate units for exhaust emission inspection on vehicles as from
initial registration (EZ) 01.01.2006 or test procedure according to Exhaust Emission Guidelines No. 4
1 / E81 - E87; 3 / E90-E93
5 / E60 - E61; 6 / E63 and E64; X3 / E83; X5 / E70, X6 / E71
Z4 / E85 and E86
MINI / R55, R56
00 03 04 (091)
Master document for vehicle-specific Service Information bulletins
All model series up to Model Y ear 2004
Situation: The constantly increasing range of different models has now grown to a degree that
makes it logical to allow vehicle-specific data to be called up concisely from a single
document.
Procedure: Call up publications concerning vehicle-specific data via the following hotspots:
Service Information bulletins, ordered by year of publication:
Year of publication Title Affected model series
1995 Sealing rings for expansion E36 M50, M52 with ASC+T
tank
1995 Overview 1996 E31, E34, E36, E38, E39
1995 Natural-gas-driven vehicles 316 g, 518 g

(CNG)
1997 Chip tuning on diesel M41, M51, M47, M57, M67

engines
1997 Support tower in oil-filter E31, E32, E34, E38 M60/1,

housing M60/2, M70, M73
2000 Transpack E52, E53
2001 Emissions test, alternative BMW, MINI

procedure
EUR only
2001 Checking V-belt ribs E53 M54, M57, M62
2001 Towing characteristics E65 E65
2002 Oil filter change R50, R53
2002 Transport mode E39, E46, E53, E65, E66
2002 Diesel flushing agent M47, M47TU, M57, M57TU,

discontinued M67, M41, M51, M21
Not USA, Canada
2002 Transmission damage BMW with automatic

during emissions test transmission
EUR only
2002 Cleaning painted hardtop E52
mounting surface
2002 Checking the electro- E65, E66, E67

mechanical parking brake
during periodic vehicle
inspection
2002 Body protection film R50, R53
Not United Kingdom
2003 Testing of four-wheel drive E30, E34, E46, E53, E83

vehicles using brake test
and performance test
stands
2003 Airbag: Repair Instructions E36, E36/7, E38, E39, E46,
for belt tensioner and/or E53, R50, R53
side airbag triggering circuit
2003 Towing E53, E83
00 02 04 (090)
Master document for workshop literature/workshop equipment
All series until model year 2004
Situation: The constantly growing range of different models has now grown to a degree that makes it
logical to allow data relevant to workshop literature/workshop equipment to be called up
concisely from a single document.
Procedure: Call up publications concerning workshop literature/workshop equipment data from the
following hotspots:
Service Information bulletins, ordered by year of publication:
Year of publication Title Affected model series
1996 Check accessories kit BMW
1997 Handling special damaged BMW, MINI

components
Germany only
1998 CBT Manager, software BMW, MINI

update of the SIP
management program
1998 MoDiC 3 diagnostic head BMW, MINI
update
1999 Deletion of microfiches BMW
1999 Remote operation using BMW, MINI

MoDiC 3
1999 Accelerated delivery of CDs BMW, MINI
1999 New delivery address for BMW, MINI

CD recycling
1999 Rescue manual BMW, MINI
2000 Handling "Q-I components" BMW, MINI

Germany only
2000 Technical Information for BMW, MINI

authorised third parties
Europe only
2001 TIS Hotline BMW, MINI
2002 KSD CD 05/2002 BMW

2002 Online publication of type BMW from E36/7, MINI
approval numbers for
original BMW brake pads Excluding USA, C
2004 Support Service for GT1 BMW, MINI

00 08 06 (277)
Nominal values supplement for emissions test on new BMW and MINI models from 01
until 07/2006
E87 / 1-Series, E46 / 3-Series, E90 / 3-Series, E91 / 3-Series, E60 / 5-Series,
E61 / 5-Series, E63 / 6-Series, E64 / 6-Series, E53 / X5, E83 / X3, E85 / Z4,
E86/Z4, MINI
Situation: The model-specific nominal values for the emissions test have been compiled for the new
BMW and MINI models launched in the period 01-06/2006.
Some previously published data records from earlier vehicles have been revised /
supplemented.
Note:
For the BMW diesel vehicles listed below which have been retrofitted with regulated diesel
particulate filter (DPF) (optional accessory 200 ”SAZ DPF”) or with unregulated particulate catalytic
converter (special equipment ”SZ PM-Kat”), only the manufacturer's model-specific opacity values
have be entered.
SAZ DPF: 1-Series/E87; 3-Series/E90; 3-Series/E91

SZ PM-Kat: 3-Series/E46; 5-Series/E60; X3/E83; X5/E53
This means that the equipment fitted must be noted when the emissions test is performed (with or without
DPF / with PM-Kat):
without DPF
Supplied with option 200 as standard or from the factory or
retrofitted to DPF with optional accessory 200
Retrofitted with diesel particulate catalytic converter supplied by BMW Parts Department.
and with reference to the different opacity limit:
Affected BMW and MINI spark-ignition and diesel vehicles
vehicles: Manufacturing period January to June 2006
E87 / 1-Series E64 / 6-Series Convertible

E46 / 3-Series E53 / X5
E90 / 3-Series E83 / X3
E91 / 3-Series Touring E85 / Z4
E60 / 5-Series E86/Z4 Coupé
E61 / 5-Series MINI diesel
E63 / 6-Series Coupé R53/MINI Cooper S John Cooper
Works GP
Procedure: During an emissions test on one of the BMW or MINI vehicles listed, reference should be
made to the manufacturer's newly compiled / revised, model-specific specifications.
Note:
These data will be programmed into the memory of the BMW emissions testers during the next
equipment maintenance by the BMW-approved equipment manufacturers:
AVL and MAHA.
Since the sole online provision of data and depending on the user concerned, the data is called
up from the BMW Web Portal, Parts Information System via the intranet, the internet or the
extranet:
ASAP”, exhaust emissions test nominal values module, under the web addresses:
or
http://www.aftersales.bmwgroup.com
Note:
Proceed as follows if vehicles are not listed in this nominal values supplement, or if vehicles are
not completely or correctly listed:
Copy the Reporting sheet provided in Enclosure 1 of this Service Information bulletin (see
sample below)
Get the testing personnel to complete/correct it
If applicable, send this with a copy of the official vehicle registration document or the printout
of the emissions test nominal data records tot he following address:
BMW AG
Servicetechnik/Marktentwicklung
Wartung und Instandsetzung, Abt. VS-13
Key word: AU-Solldaten
Fax No. +49-89-382-41788
D-80788 Muenchen
The error(s) will then be corrected and included in the next update.
These emissions test nominal values apply exclusively to emissions tests carried out on customer-owned
vehicles and have no direct link to homologation values.
If national authorities stipulate different conditions and specifications for the official emissions test applicable in
the respective country and the use of emissions test nominal values specific to the manufacturer or model is
not permitted, please take this into account.
00 20 04 (163)
Nominal values supplement for emissions test on new BMW and MINI models from
01/2004 until 12/2004
E87, E46, E61, E63, E64, E53MÜ/X5, E83/X3, E85/Z4, R50, R53
BMW and MINI models launched in 2004.
This mainly affects 1-Series / E87, 5-Series / E61 and
6-Series / E63 and E64 vehicles.
For the existing data records for the model series E46 and E53, the new BMW key numbers issued as part of
model revisions have been included in the existing data records.
On MINI models with ”closed-loop catalytic converter”, the KBA type designation given in the vehicle papers
was changed from R50 to MINI. This change has now been made in the data sheets.
It should be noted that on the newly launched 6-cylinder engine N52 and the Motorsport 10-cylinder engine
S85B50, which have a Bosch 4.9 planar broadband oxygen sensor, a voltage range is now specified instead of
the current specification previous customary for broadband oxygen sensors.
Affected vehicles:BMW spark-ignition and diesel vehicles, production 01/2004 until 12/2004 - the following
model series:
1-Series/E87 X5/E53
(after model revision)
3/E46 X3/E83
5-Series/E61 Z4/E85
6/E63 MINI/R50 (
6/E64 MINI/R53
Procedure: During an emissions test on one of the BMW vehicles listed, reference should be made to
the manufacturer's newly compiled / revised, model-specific specifications.
Since the activation exclusive online provision (user-dependent), the data can now only
be called up via the internet or extranet from the BMW web portal ”ASAP” (Aftersales Assistance Portal),
”Exhaust emissions nominal values” module.
Dealerships attached to the BMW service organisation should use their usual ASAP access.
Workshops performing emissions tests that are not part of the BMW service organisation or appropriate
authorities can access the necessary data at the following web addresses:
or
However, these user groups must first apply for a user ID from the BMW subsidiary or importer in the country
concerned.
Note:
These data will be installed in the memory of the tester during the next service of the BMW
emissions testers by the equipment manufacturers approved by BMW:
Companies AVL and MAHA
Note:
If you find that vehicles are either not listed, or that a listing is incomplete or faulty, you are advised to:
Print out the feedback sheet provided in the collection of emissions test nominal values under ”Extras”
(please refer to sample below).
The mechanic carrying out the emissions test must fill out this sheet explaining/correcting the error(s).
If necessary, send by fax to BMW's Central Service - Repair Information, Dept. VS-21 together with a
copy of the car's official registration papers or of the printout of the nominal values
(fax no.: +49-89-382-41788)
We will then correct accordingly in the next update.
00 01 05 (191)
Nominal values supplement for emissions test on new BMW, MINI and Rolls-Royce
models from 01 until 12/2005
E87 / 1-Series, E46 / 3-Series, E90 / 3-Series,
E91 / 3-Series, E60 / 5-Series, E61 / 5-Series,
E63 / 6-Series, E64 / 6-Series, E65MU / 7-Series, E66MU / 7-Series, E53MU /
X5,
E83 / X3, E85 / Z4, R50/MINI,
R53/MINI, R52/MINI, RR01
BMW and MINI models launched in the period 01-12/2005.
In addition, the nominal data for the emissions test are listed for Rolls-Royce.
It should be noted that on all 6-cylinder engines N52 and on the Motorsport 10-cylinder engine S85B50 with a
Bosch 4.9 planar broadband oxygen sensor, the current range must, like for other broadband oxygen sensors,
be specified for the additional test on non-set readiness codes. However, on the above engines, the LSU 4.9
broadband oxygen sensor has a different value range to the Bosch LSU 4.2 broadband oxygen sensors.
Important:
The information given in SI 00 15 03 (052), published in 12 / 2003 concerning voltage
measurements on this planar broadband oxygen sensor is no longer valid!
For BMW diesel vehicles, different opacity limits are given, depending on the following installation status of the
DPF (diesel particulate filter):
without DPF
as standard with DPF or delivered from the factory with DPF as per option 200, or retrofitted with the same
with diesel particulate catalytic converter retrofit sets supplied by BMW Parts Service.
On BMW diesel vehicles with standard (and thus regenerating diesel particulate filter), there is no need to
repeatedly open the throttle to condition the exhaust system (eliminate deposits of soot) before carrying
out the actual opacity test.
Note: For the new test procedure ”Diesel with OBD” applicable in Germany since 1 October 2005, the
corresponding enclosures have been incorporated into the nominal data sheets for diesel vehicles.
Affected vehicles:BMW spark-ignition and diesel vehicles, model year January to December 2005:
MINI; Rolls-Royce
E87 / 1-Series E65MU / 7-Series

E46 / 3-Series E66MU / 7-Series
E90 / 3-Series E53MU / X5
E91 / 3-Series Touring E83 / X3
E60 / 5-Series E85 / Z4
E61 / 5-Series R50 / MINI Cooper
E63 / 6-Series Coupé R53 / MINI Cooper S
E64 / 6-Series Convertible R52 / MINI Convertible
RR01
Procedure: During an emissions test on one of the BMW vehicles listed, reference should be made to
the manufacturer's newly compiled / revised, model-specific specifications.
Note:
These data will be programmed into the memory of the BMW emissions testers during the next
equipment maintenance by the BMW-approved equipment manufacturers:
AVL and MAHA.
Since the sole online provision of data and depending on the user concerned, the data is called
up from the BMW Web Portal, Parts Information System via the intranet, the internet or the
extranet:
ASAP”, exhaust emissions test nominal values module, under the web addresses:
or
Note:
Proceed as follows if vehicles are not listed in this nominal values supplement, or if vehicles are
not completely or correctly listed:
Copy the Reporting sheet provided in Enclosure 1 of this Service Information bulletin (see
sample below)
If applicable, send this with a copy of the official vehicle registration document or the printout
of the emissions test nominal data records tot he following address:
BMW AG
Servicetechnik/Marktentwicklung
Wartung und Instandsetzung, Abt. VS-13
Key word: AU-Solldaten
Fax No. +49-89-382-41788 D-80788
Muenchen, Germany
00 03 09 (528)
Supplement for target exhaust emission data from 04/2007 to 03/2009 Test procedure
for lean-mix petrol engines. Amended test procedure and flat rate units for exhaust
emission inspection on vehicles as from initial registration (EZ) 01.01.2006 or test
procedure according to Exhaust Emission Guidelines No. 4
1 / E81 - E87; 3 / E90-E93; 5 / E60 - E61; 6 / E63 and E64; X3 / E83; X5 / E70,
X6 / E71, Z4 / E85 and E86, MINI / R55, R56
Situation: 1. Type-specific target data for the exhaust emission inspection have been compiled for
BMW models introduced in the period from 04/2007 to 03/2009. Changes/additions have
in part been made to data records already published for earlier vehicles.
2. German legislation has adapted the testing procedure for all vehicles as from initial registration (EZ)
01.01.2006 to the technical advancement of these vehicles, e.g. EURO-4. This means only the OBD data need
to be read and evaluated as part of the exhaust emission inspection. An exhaust emission measurement is to
be additionally carried out only in rare cases where not all OBD readiness tests return a positive result, e.g.
after clearing fault code memory.
For this purpose, the exhaust emission operator prompting has been adapted to the Exhaust Emission
Guideline No. 4 which is compulsory for these vehicles as from 01.12.2008.
3. The flat rate units have also changed in line with the amended test procedure.
Affected vehicles:BMW and MINI petrol and diesel engine vehicles, initial registration from 04/2006 to
03/2009
E81-E87, E90-E93, E60-E61, E63-E64, E70-E71, E83, E85-E86. E65 and F01, F02. MINI /
R55, R56
Procedure: 1. The newly compiled or revised, indices manufacturer's data (target exhaust emission
inspection data) are to be used while conducting the exhaust emission inspection on the
indices BMW or MINI vehicles.
Note:
These data will be loaded in the tester menu by the BWM-approved tester manufacturer: AVL and
MAHA as part of the next maintenance procedure on the BMW exhaust emission testers.
Since introducing the exclusive online provision data -user-dependent-, these data can be
retrieved on the Intranet, Internet or Extranet from the BMW Web-Portal, Technical Parts
Information System: ASAP”, module - exhaust emission target data, under the web addresses:
or
Note:
copy the Reply forms provided in Enclosure 1 to this SI
if necessary, send by fax to BMW's Central Service - Repair Information, Dept. VS-35 together with a
copy of the car's official registration papers or of the printout of the nominal values. (fax No.: 089 -382-4 17
88
2. Using the new test procedure conforming to Guideline 4:
A. Reading and evaluation of OBD data.
If the status of the function indicator lamp is "MIL-Off",
there are no fault codes in Mode 3 and
and if all available test readiness codes are set positive, the exhaust emission inspection is
passed and can be concluded with a printout of the test certificate or test verification.
The exhaust emission inspection is not passed at MIL-On or if fault codes are set.
B. Supplementary exhaust emission measurement:
If not all available test readiness codes are set to positive, e.g. after previously clearing the fault code
memory, the previously standard exhaust emission measurement must be additionally carried out.
Petrol engines:
Determining CO content at idle speed and elevated idle speed*
Lambda at elevated idle speed*
Carrying out Lambda_Regelkreis test by means of substitute procedure, i.e. measuring the oxygen
sensor current with the generic scan tool*
Diesel engines:
Measurement of idle speed and maximum engine speed*
Measurement of exhaust gas opacity*
*= see type-specific exhaust emission target data

Note:
The following deviations in the additional exhaust emission measurement that may be necessary
apply to BMW vehicles with lean-mix petrol engines such as the N43 and N53 that are equipped
with a DeNOx storage catalytic converter:
Lambda: 0.97 -2.30
Current of lambda control sensors: -0.115 - +1.325 mA
The exhaust emission measurement must be repeated if regeneration of the DeNOx storage
catalytic converter, which takes max. 10 sec and leads to lambda values substantially lower than
0.97 or CO values higher than 3 vol.-%, is initiated by the DME control unit during the exhaust
emission measurement.
3. New flat rate units for the exhaust emission inspection for vehicles with first registration as from
01.01.2006:
Petrol engines: Diesel engines

00 00 128 § Exhaust emission inspection 3 FRUs 3 FRUs
only with OBD data
00 00 528 § Exhaust emission inspection 1 FRU 1 FRU
only with OBD (for inspection)
00 00 850 Supplementary exhaust emission 2 FRUs 2 FRUs
measurement
The previous FRUs are to be used for vehicles built before initial registration date 01.01.2006, i.e. general
implementation of exhaust emission measurement.
Where applicable, other requirements relating to the exhaust emission inspection stipulated by national
authorities which do not permit the use of manufacturer or type-specific data must be observed.
00 05 11(686)
Supplement for target exhaust emissions inspection data of BMW and MINI vehicles
from 04/2009. Modified test specifications for petrol lean-mixture engines N43 and N53.
Test procedure for hybrid vehicles
1 / E81 - E87; 3 / E90-E93;5 / F10 - F11,F18; GT5 / F07; X1 / E84; X3 / F25; X5 /
E70, X6 / E71 - E72, Z4 / E89; MINI / R55 - R57, R60;
Situation: The type-specific target exhaust emissions inspection data has been issued for the BMW
models introduced from 04 / 2009. Changes/additions have in part been made to data
records already published for earlier vehicles, in particular with N43 lean-mixture
N53engines.
Vehicles concerned:BMW and MINI petrol and diesel-engine cars, first registration from 04/2009
E81-E89, E90-E93, E70-E72, F01-F07, F10 – F18;F25; MINI / R55 - R57, R60; Rolls-
Royce RR04;
Procedure: 1. The newly compiled or revised type-specific manufacturer data (target exhaust
emission inspection data) are to be used while conducting the exhaust-gas test on the
BMW or MINI vehicles.
Note:
This data will be loaded for next maintenance in the tester menu by the BMW approved
equipment manufacturer: AVL and MAHA as part of the next maintenance procedure on the BMW
exhaust emission testers.
Since introducing the exclusive online provision data -user-dependent-, these data can be
retrieved on the Intranet, Internet or Extranet from the BMW web portal, Technical Parts
Information System: ASAP”, module - emissions test nominal values, under the web addresses:
or
Note:
copy the Reply forms provided in the enclosure to this SI
if necessary, send by fax to BMW AG Central Service - Repair Information, Dept. VH-54 together with a
copy of the vehicle's official registration papers or of the printout of the nominal values. (fax No.: +49 89
382 4 17 88).
2. Change of speed and lambda sensor specifications for lean mixture engines N43 and N53
2.1 Lambda sensor change for N43 and N53:
If necessary in the case of the additional exhaust test on the end pipe, if the readiness codes of the OBD are
not positively set or are incomplete, the following lambda sensor values apply for BMW vehicles with petrol
lean-mixture engines such as N 43 and N 53 for idle speed and increased idle speed:
0,7 - 4,0
Relevant current value range of the lambda control sensors:
- 1.60 to + 1.82 mA.
The exhaust emission measurement must be repeated if regeneration of the NOx catalyst storage converter,
which takes max. 10 sec and leads to air ratios substantially lower than 0.97 or CO values higher than 3 vol.-%,
is initiated by the DME control unit during the exhaust emission measurement.
2.2 Behaviour of the "increased" idle speed only for N43:
The engine control system MSD80 and MSD81 contains a time- and speed-dependent component protection
function to avoid thermal damage to the N43 engines.
This means that for a stationary vehicle ( v = 0 km/h) and acceleration, e.g. to bring the engine to the operating
temperature quicker, after 150 seconds the increased idle speed is limited to a max. 2000 rpm. At the same
time the engine warning light (EML) is controlled and a fault code (0x2F91) entered in the shadow memory
(ScanTool-Mode 7).
For the performance of the emissions measurement in the legally required test step CO and lambda
sensor measurement at increased idle speed, this means:
To achieve the operating temperature the engine cannot be operated in a stationary position at an
engine speed greater than 1900 rpm.
Then the test step "CO and lambda sensor measurement at increased idle speed", according to BMW
specification 2300 – 2700 rpm, can be performed within a max. 150 seconds.
3. Exhaust emissions inspection for BMW hybrid vehicles BMW 7-series Active Hybrid (F04) and BMW X6
Active Hybrid (E72).
The exhaust emissions must be inspected according to the two-stage test procedure valid for vehicles from
01.01.2006:
1. Reading and evaluation of OBD data
MIL function; P codes in Mode 3; status of the readiness codes (RC)
If all vehicle-specific relevant readiness codes (RCs) are not positively set, i.e. the OBD system is not
ready for testing, then the next step must also be performed.
2. Exhaust gas end pipe inspection with the following test criteria:
Petrol engine with G-cat:
CO in idle state > max. 0.3 Vol-%
CO increased idle state > max. 0.2 Vol-%
Lambda 0.97-1.03 in increased idle state (n = 2300 – 2700 rpm)
Closed loop test i.a.w. replacement procedure: i.e. current measurement of the lambda control sensors
as per manufacturer specifications in idle state.
Diesel engine:
Check the idle state and maximum speed with no load; values as per manufacturer specifications
Smoke density at free acceleration: K value according to manufacturer specifications or for vehicles with
controlled particulate filter (PM-5) max. 0.5 m-1
Special features: Operation of the combustion engine at V = 0 km/h. Perform exhaust emissions inspection if
step 2 = emission measurement required:
1. For the BMW 7-Series Active Hybrid the combustion engine can be operated in a stationary state
without additional intervention due to the mild hybrid concept.
2. For the BMW X6 Active Hybrid on account of the full hybrid concept: "Start-up generally in electric motor
mode" the following steps must be performed for the operation of the combustion engine in a stationary
state:
I. Required operating mode: "Detection of driver present"; i.e. driver's door must be open and driver's seat
belt not used!
II. Engine start by pressing Start button
III. Gearbox selector lever in position N!
IV. Gas pedal for idle state emission measurement not activated. Note: Depending on the state of charge of
the high-voltage battery (HV) an increased load can be effected for the battery charge also in idle
operation.
V. Press the gas pedal for increased idle state measurement at n-mot = 2300 - 2700 rpm and hold for
prescribed measurement period (30 sec).
Where applicable, other specifications relating to the exhaust-gas test stipulated by national authorities which
do not permit the use of manufacturer or type-specific exhaust emissions data must be observed.
00 01 02 (800)
Supplement of nominal values for emissions test on new BMW models since 09/2001
E65, E46, , E53 / X5 4.6is, , E39 / Diesel
Situation: Model-specific nominal values for emissions test have been drawn up for the new BMW
models being launched between autumn 2001 and spring 2002.
For 5-series/E39 diesel vehicles with M47 and M57 engines and option 201 (RME
operation), the existing manufacturer's limits for exhaust gas opacity have been supplemented with special
limits for RME (rapeseed oil methyl ester) operation.
For the E46 Compact/316ti with N42 engine, the values for oxygen sensor measurements have been
corrected to current values compared to the data contained in the emissions test nominal values CD, 3rd
edition 02/2001.
Enclosure 1 Spark-ignition engine with closed-loop catalytic converter E46 -

316i Saloon and Touring
Enclosure 2 Spark-ignition engine with closed-loop catalytic converter - E46
316ti Compact
318i Saloon and Touring
318ci Coupé and Convertible
318ti Compact
M3 Convertible
735i Saloon
745 Saloon
X5-4.6 is Saloon and Touring
Enclosure 10 Diesel engine E46 - 318d Saloon and Touring
Enclosure 11 Diesel engine - E46 320d Saloon and Touring
Enclosure 12 Diesel engine - E46 320td Compact
Affected vehicles:BMW spark-ignition and diesel vehicles, produced 09/2001 - mid-2002

E46/M47uL and TU
E46/N42
E46/S54 Convertible
E39/M47 and M57 with RME operation
E65/N62
E53/X54.6is
Procedure: Subject to requirements in different countries, the manufacturer's type-specific
specifications described in the enclosures form the basis of the emissions test on the
above BMW vehicles.
Notes:
This data will be fed into the memory of the BMW emissions tester during a service update by the equipment
manufacturer AVL from January 2002 to retrofit the ScanTool.
Persons conducting emissions tests who are not part of the BMW dealer organisation can call up this data
through the internet from the BMW Online Service System (OSS):
www.bmw-service.de > Module TIS>Document type Service Information>Group 00 or by entering the Service
Information number 00 01 02 (800).
Moreover, this data can also be taken from the data catalogues of the free-market repair data publishers (e.g.
DAT, Eurotax, Autodata) once their updates have been published.
Note:
If you find that vehicles are either not listed, or that a listing is incomplete or faulty, you are kindly requested to:
Print out the reporting sheet, which can be found under ”Options” in menus of the BMW emissions test
nominal values CD 3,
If necessary, send to the Central Service / Product Support, department VS-24 together with a copy of
the car's official registration papers or of the printout of the nominal values (fax no. +49 89-382-44928)
These nominal values only apply to emissions tests on vehicles in the possession of customers and have no
direct relevance to homologation data.
If national authorities stipulate other requirements for the emissions test, rendering the manufacturer's model-
specific nominal values inapplicable, these must be observed.
00 20 16 (403)
Test instructions for the exhaust gas test (AU) on BMW vehicles with diesel engines
from European emission classification "EURO 6"
BMW and MINI diesel vehicles with exhaust emission stage "EURO 6" and
from vehicles: EU exhaust gas code "W" or German emission key number
"36W0". Depending on the model introduced from production 07/2014.
Situation: 1. The European parliament and the EU Council have adopted new test specifications for
periodic vehicle inspection with the guideline 2014/45/EU in April 2014. Objective was to
implement new findings in traffic conditions and to adapt the test according to the technical
state of the vehicles.
The implementation regulations according to Enclosure I, section 8.2.2.2 of this guideline allow the exhaust
emission behaviour for vehicles from EURO 6 to be classified by reading/evaluating the on-board diagnosis
data (OBD) and associated vehicle manufacturer's specifications.
The BMW/MINI vehicles from the exhaust emission stage "EURO 6_Klasse W" contain extended and stringent
OBD test criteria and are, thus, as a rule to be checked by evaluating the OBD data and observing the
additional manufacturer's instructions. This test method corresponds to the state of the technology installed in
these vehicles.
2. The German Department of Transport, in September 2014 by publishing the "Guideline for the
implementation of the exhaust gas test", has adopted the minimum requirements of the above-mentioned EU
Directive and has modified them slightly according to the field experiences in Germany. The previous
procedure, for all vehicles from first registration 01.01.2006, that is, from exhaust emission stage EURO 4, the
two-stage procedure is retained for the time being:
Stage 1: Reading and evaluation of OBD data;
Stage 2: If not all readiness codes are set to positive, then in addition an exhaust tailpipe measurement has to
be carried out, in this case opacity measurement, under free acceleration and evaluation of the "Official sticker
value" using certified exhaust emission devices. This applies until further notice even for EURO 6 vehicles until
renewed findings equivalent to "OBD vs.. Exhaust gas measurement" are available.
Vehicles concerned:BMW and MINI diesel vehicles with exhaust emission stage "EURO 6" and from
vehicles: EU exhaust gas code "W" or German emission key number "36W0".
Depending on the model introduced from production 07/2014.
Procedure: Official test scopes

1. EU wide test scopes (without Germany):
Vehicle and vehicle documents match;
Recording vehicle data for verification certificate;
1.2 Exhaust gas classification test:

Check whether the vehicle corresponds to the exhaust emission stage/code "EURO 6 W" or "36W0". To do
this, read out corresponding data from the certificate of acceptance part 1 (vehicle registration papers) in line
14 or in field 14.1.
1.3 Check by reading and evaluating the OBD data:

Connect one of a Generic ScanTool corresponding to the current OBD standards on the vehicle diagnosis
interface. (Use ScanTools with printer output only.)
1.3.1 Functional test of the interface connecting ScanTool to the EOBD of the drive-control units
Display: Type of the OBD report and the number of emission-relevant control units
See Enclosure 1: Graphics of all ScanTool modes or services
Please refer to Enclosure 2: ScanTool read out and results to diesel vehicle
OBD diagnosis connection in the vehicle
1.3.2 Malfunction indicator lamp check (MIL = malfunction indicator lamp)
Figure of the malfunction indicator lamp (MIL)
Visual inspection of the function of malfunction indicator lamp (MIL)

Ignition on – engine off - MIL lit = OK
Ignition on – engine off - MIL not lit = not OK
Ignition on – engine running - MIL off = OK
Ignition on – engine running - MIL lit = not OK
Reading the status of the MIL from the ScanTool in Mode 1-
If the ScanTool output is "MIL Off": = OK
If the ScanTool output is "MIL On": = not OK
1.3.3 Status and evaluation of OBD readiness test (Readiness codes) in the ScanTool mode 1
Read out and evaluate individual readiness test codes in the two OBD categories:
Group B: Continuous monitoring
Group C: Non-continuous monitoring
Note: In the ScanTool, following selection is necessarily applicable:
"Delete readiness test for fault code"!
Here, the Readiness tests from several driving cycles are displayed and the probability is highest that all
supported RCs are set to positive. When selecting "Readiness test of this cycle", the supported RCs are
usually not set to positive.
Generally, immediately before the exhaust-gas test without a wilful occasion, for example, if no drivability
complaints have been made by the customers, the fault memory should not be deleted, because this will
also delete all readiness test codes, in addition to the error codes.
Only within the scope of service review or for customer complaints, the fault memory should be viewed in
mode 3 with regard to possible repeatedly confirmed errors shortly before the exhaust-gas test. If errors exist
that would lead to a failure of the exhaust-gas test, carry out a repair and then delete the fault memory. Then 2-
3 driving cycles* should be carried out in which the readiness of the individual systems can be reset.
* = Engine start, acceleration phases, constant-speed driving, overrun phase, idle operation and stopping the
engine
Readiness tests (Readiness codes) Diesel engine
Continuous monitoring Non-continuous monitoring

- Byte B data - - Byte C data -
0 misfire 0 NMHC catalytic converter
1 Fuel system 1 Nitrogen oxide catalytic converter/SCR system
2 Components 2 -Free-
3 -Free- (if necessary O-/D monitoring) 3 Charging pressure
4 -Free- (if necessary air conditioning)
5 Exhaust gas sensor
6 Particulate filter
7 Exhaust gas recirculation system
Table: Designations of the Readiness Codes
Manufacturer's specifications for Readiness Code - Evaluation:

In the group B "continuous Überwachung_Data byte B", all parametrised and supported RCs must be set
to positive. that is, the electrical check of the sensors/actuators has lapsed in all functions; to do this usually a
1-2 minute engine operation in idle position is sufficient. If one of these RCs is not set to positive even when
the engine is running (also referred to as "test not carried out"), then the exhaust-gas test shall be
evaluated as failed.
In the Group C, "non-continuous Überwachung_Data byte C" all, but at least 4, parametrised or
supported RCs should be checked to be positive. Few "long-time needed" RCs cannot yet be set to
positive! (also referred to as "test not carried out").
Reason: Their fault set conditions require a longer journey with different load conditions, speeds and specific
atmospheric conditions after fault memory deletion.
For BMW and MINI diesel fuel engines from exhaust emission stage EURO 6, the following 3 RCs:
Nitrogen oxide/SCR system, particle filter, exhaust gas sensor may be exempted from RC evaluation, that
is, not yet set to positive or Display bit 1.
Note:
The set result by a binary indication of the individual RCs is:
0 = checked at least once or diagnosis not supported
1 = Components displayed as not yet fully checked. The figure below shows the
Evaluation matrix:
Readiness Codes
Continuous testing_ Byte B data- Data: Petrol and diesel-engine vehicles
Bit Supported/bit Test Permissible bit values of the performed RCs for the
carried exhaust-gas test evaluation at OK or passed
out/ bit
0 Misfire Yes = 0 / No = Yes = 0 / 0
1 No = 1
1 Fuel system Yes = 0 / No = Yes = 0 / 0
1 No = 1
2 General Yes = 0 / No = Yes = 0 / 0

components 1 No = 1
3 Free- (if necessary Yes = 0 / No = Yes = 0 / 0 if implied; Otherwise even 1
O-D monitoring) 1 No = 1
Non-continuous tests _ Data byte C/D data: Only diesel vehicles
Bit
0 NMHC catalytic converter Yes = 0 / No = 1 Yes = 0 / No = 1 0
1 Nitrogen oxide catalytic converter/SCR system Yes = 0 / No = 1 Yes = 0 / No = 1 0 or 1
2 free Yes = 0 / No = 1 Yes = 0 / No = 1 0
3 Charging pressure Yes = 0 / No = 1 Yes = 0 / No = 1 0
4 Free- (if necessary air conditioning) Yes = 0 / No = 1 Yes = 0 / No = 1 0 or 1
5 Exhaust gas sensor Yes = 0 / No = 1 Yes = 0 / No = 1 0 or 1
6 Diesel particulate filter Yes = 0 / No = 1 Yes = 0 / No = 1 0 or 1
7 Exhaust gas recirculation system Yes = 0 / No = 1 Yes = 0 / No = 1 0
Graphic: Evaluation matrix of the readiness test bits
1.4 Record status of the fault memory in ScanTool mode 3*

(* = Mode 3 means storage of errors which have been confirmed over multiple driving cycles).
If standardised Powertrain codes, for example, P0 xyz, P2 uvw or manufacturer-specific Powertrain
codes, e.g P1 xyz, P3 uvw, are stored: Test = not OK
If no Powertrain codes are stored: Test = OK
1.5 Identity check of the chassis number (VIN) according to the comparison via ScanTool Mode 9:
Read out chassis number (VIN = Vehicle Identification Number) from ScanTool Mode 9 and compare it with the
vehicle type plate:
If the VINs deviate from each other: Test = not OK
1.6 OBD final evaluation:

If the:
MIL - function check and MIL - status are OK,
the RC evaluation, taking into account "long-time RCs" not relevant to the set, is positive
no errors are stored in mode 3,
the VIN comparison: Vehicle to ScanTool -Mode 9- information is identical,
then the exhaust-gas test is to be concluded as "passed".
If one of the aforementioned points is not OK, the exhaust-gas test via OBD is considered failed.
The OBD data MIL and RC status from Mode 1; Error codes from Mode 3 and VIN from Mode 9 are to be
printed on the verification certificate.
Note: If data communication is not possible in the event of several connection attempts between the
ScanTool and the vehicle-side interface (OBD socket), the emissions test is classed as “not passed” and the
vehicle is to be repaired.
2. Test scopes for exhaust-gas test on EURO 6 diesel vehicles in Germany:

In Germany, at present, the two-stage test procedure for all vehicles of categories M (passenger cars) and
N (trucks) from the date of first registration 01.01.2006* is applicable even for EURO 6 vehicles with
obligatory exhaust-gas test operator prompting. (* = from EURO 4 / IV) In addition, the exhaust-gas test may
be performed on these vehicles from 01.06.2015 only with the operator prompting according to "Exhaust-gas
test - devices user guide 5".
2.1. Level 1 = OBD - check:

Read out and evaluate the OBD data, as described in section 1.1 - 1.6, but with the following changes:
Section 1.2 Exhaust emission classification check on EURO 6 omitted because all vehicles from first
registration 01.01.2006 (from EURO 4) are primarily checked via the OBD.
In section 1.3.3, all continuous and all non-continuous supported readiness codes must be set to
positive (bit = 0).
If the readiness codes of the OBD system operated by the engine control unit are not or not
completely set to positive, that is, the OBD system itself is not yet ready for testing, for example,
because the fault memory was deleted shortly before, an opacity measurement must additionally be
carried out according to Section 2.2.
2.2. Level 2 = Exhaust gas opacity measurement as additional check under the following precondition:
Note: The following procedure generally also applies to all diesel vehicles before the first registration
01.01.2006. See also the BMW Service Information "Test instructions for the exhaust-gas test on BMW
vehicles with diesel engines" from 04/2012.
2.2.1 Visual inspection of emission-relevant components:

Note: This test step will be deleted from the new version of §29_StVZO in accordance with 47th amendment
regulation as from 01.07.2012, as the visual inspection is an integral part of the technical vehicle inspection and
thus the same components are not inspected twice.
2.2.2 Setting check: Idle position and maximum speed unloaded according to the manufacturer's specification.
See also BMW exhaust-gas test nominal data.
2.2.3 Effective check:

Determining the exhaust gas opacity at the exhaust system tailpipe during “free acceleration” at operating
temperature, i.e. with engine oil temperature at minimum 60 °C with selector lever position in “Neutral”. Free
acceleration is defined as revving the engine from idle up to maximum speed at no load in response to a swift
opening of the throttle. The accelerator pedal must be depressed quickly and continuously within max.
1 second from the idle stop to the full load stop. To determine the actual opacity state (opacity coefficient k in
m-1), it is necessary to create the arithmetical mean from three engine start-ups. If the opacity value of 1st
engine start-up is at least 30 % below the limit value, further start-ups can be omitted.
Caution!
In few cases, under certain circumstances, it could lead to a state where the DME activates an
engine speed limitation to 2000 rpm for the reason of component protection. After the terminal
change, this protective function is automatically deactivated again.
Graphic: Opacity characteristic during engine start-up = free acceleration

2.2.4 Opacity limit values:
For all diesel vehicles, since the publication of the German Implementing Directive only the "Sticker value"
indicated on the vehicle type plate applies according to EU Directive 72/306/EEC.
BMW type plate with “sticker value” 0.51 in the small rectangle
If sticker value is not available or cannot be used on technical grounds, the following applies:
for vehicles which were brought in the market for the first time before 1 October 2006: maximum 2.5 m-1,
based on measuring mode B;
for vehicles which were brought in the market for the first time from 1 October 2006 and before 1
September 2015: maximum 1.5 m-1, based on measuring mode B;
for vehicles from emission key 36xx or 66xx: (= EURO 6) maximum 0.5 m-1, based on measurement
mode B.
Note: In Germany it is possible to select the mode for determining the opacity coefficient, i.e. its measuring
circuit time constant, in the emission tester:
Mode A: = “unfiltered”, i.e. < 0.050 sec
Mode B: = “filtered”, i.e. 0.90 – 1.10 sec
Generally mode B is to be used for BMW vehicles throughout the EU and in Germany in line with EU Directive
72/306/EEC.
General notes:
The manufacturing stage emissions test nominal values, for example, engine speed ranges; opacity threshold
values are shown in the BMW emissions test nominal data acquisition related to the type.
BMW Aftersales Portal and for “third-party users”, via the Internet from the BMW web portal Technical Parts
information system: ASAP”, module - emissions test nominal values
at the web addresses: http://www.parts.bmwgroup.com
Updates are usually issued in April and October every year.
Incidentally, in Germany, the new "Guidelines for conducting exhaust gas test on vehicles according to Section
6.8.2 of Enclosure VIIIa German road traffic licensing regulations (StVZO) from 30.09.2014" are applicable.
Country-specific specifications of other countries must be given priority in any case to this SI
specifications.
Enclosure 1 "ScanTool services"

Reading and display functions of the OBD - Generic ScanTools
Select scan tool connected to

OBD functions interface
Detect the EOBD or US OBD-2 Example: Society of Automotive Engineers J 1850,
diagnosis report International Organization for Standardisation 9141-2,
International Organization for Standardisation 14230-4
(= Key Word Protocol-2000 Fast), International
Organization for Standardisation 15765-4 (= CAN);
Service 01 Malfunction indicator lamp status; Listing of all supported systems/functions;
Readiness code; Number of
stored errors; call-up of current
engine data (e.g.: n-mot;
temperatures; load conditions
etc.)
Service 02 Calling-up "Freeze Frame” data to Marginal conditions in which error codes were set
stored error codes, for example,
to P0 100:for n = 1,200 revolutions
per minute; Tw = 22°C; Partial
load= 10%, v = 0 km/h, etc.
Service 03 Calling-up all set error codes. g. Listing of all fault codes that make the malfunction
P0100 “Air flow circuit indicator lamp light up ; faults that are confirmed over
malfunction” multiple driving cycles
Service 04 Deleting the OBD error codes, Only permissible for test purposes after repair or if
Freeze Frame and all other data renewed driving cycle occurs
Service 05 Monitoring of oxygen sensors, for Checking the current control voltage - Engine must be
example, sensor 1: 0.35 <--> 0.87 running
volts
Service 06 Call-up of the shadow fault Not continuously monitored functions, for example, only
memory, e. g. P0410 “Secondary 1 x after each engine start
air feed malfunction”
Service 07 Call-up of the shadow fault Continuous monitoring; fault codes stored here must
memory, for example, P0133 not yet lead to the lighting up of malfunction indicator
oxygen sensor 1 = slow response lamp
Service 08 System or components, for Only required for in-depth diagnosis steps in Service
example, valve actuation for fuel
tank ventilation system
Service 09 Vehicle identification (chassis for example, for documentation; as well as data for
number control units number; official field monitoring
mileage with malfunction indicator
lamp ON)
Service Display permanent error codes for example, non-deletable NOx codes
$0A
00 1916 (402)
Test instructions for the exhaust gas test (AU) on BMW vehicles with petrol engines
from European emission classification "EURO 6"
BMW, BMW i, BMW M, MINI and Rolls Royce petrol engine vehicles with
exhaust emission stage "EURO 6“ and from EU-exhaust gas-code "W“ , or
German emission key number"36W0". Depending on the model introduced
from production 07/2014.
Situation: 1. The European parliament and the EU Council have adopted new test specifications for
periodic vehicle inspection with the guideline 2014/45/EU in April 2014. Objective was to
implement new findings in traffic conditions and to adapt the test according to the technical
state of the vehicles.
The implementation regulations according to Enclosure I, section 8.2.2.2 of this guideline allow the exhaust
emission behaviour for vehicles from EURO 6 to be classified by reading/evaluating the on-board diagnosis
data (OBD) and associated vehicle manufacturer's specifications.
The BMW/MINI vehicles from the exhaust emission stage "EURO 6_Klasse W" contain extended and stringent
OBD test criteria and are, thus, as a rule to be checked by evaluating the OBD data and observing the
additional manufacturer's instructions. This test method corresponds to the state of the technology installed in
these vehicles.
2. The German Department of Transport, in September 2014 by publishing the "Guideline for the
implementation of the exhaust gas test", has adopted the minimum requirements of the above-mentioned EU
Directive and has modified them slightly according to the field experiences in Germany. The previous
procedure, for all vehicles from first registration 01.01.2006, that is, from exhaust emission stage EURO 4, the
two-stage procedure is retained for the time being:
Stage 1: Reading and evaluation of OBD data;
Stage 2: If not all readiness codes are set to positive, then in addition an exhaust tailpipe measurement has to
be carried out, in this case opacity measurement, under free acceleration and evaluation of the "Official sticker
value" using certified exhaust emission devices. This applies until further notice even for EURO 6 vehicles until
renewed findings equivalent to "OBD vs.. exhaust gas measurement" are available.
Vehicles concerned:BMW, BMW i, BMW M, MINI and Rolls Royce petrol engine vehicles with exhaust
emission stage "EURO 6“ and from EU-exhaust gas-code "W“ , or German emission
key number"36W0". Depending on the model introduced from production 07/2014.
Procedure: Official test scopes

1. EU wide test scopes (without Germany):
Vehicle and vehicle documents match;
Recording vehicle data for verification certificate;
1.2 Exhaust gas classification test:

Check whether the vehicle corresponds to the exhaust emission stage/code "EURO 6 W" or "36W0". To do
this, read out corresponding data from the certificate of acceptance part 1 (vehicle registration papers) in line
14 or in field 14.1.
1.3 Check by reading and evaluating the OBD data:

Connect one of a Generic ScanTool corresponding to the current OBD standards on the vehicle diagnosis
interface. (Use ScanTools with printer output only.)
OBD diagnosis connection in the vehicle

1.3.1 Functional test of the interface connecting ScanTool to the EOBD of the drive-control units
Display: Type of the OBD report and the number of emission-relevant control units
See Enclosure 1: Graphics of all ScanTool modes or services
Please refer to Enclosure 2: ScanTool read out and results to diesel vehicle
1.3.2 Malfunction indicator lamp check (MIL = malfunction indicator lamp)
Figure of the malfunction indicator lamp (MIL)
Visual inspection of the function of malfunction indicator lamp (MIL)

Ignition on – engine off - MIL not lit = not OK
Ignition on – engine running - MIL off = OK
Ignition on – engine running - MIL lit = not OK
Reading the status of the MIL from the ScanTool in Mode 1-
If the ScanTool output is "MIL Off": = OK
If the ScanTool output is "MIL On": = not OK
1.3.3 Status and evaluation of OBD readiness test (Readiness codes) in the ScanTool mode 1
Read out and evaluate individual readiness test codes in the two OBD categories:
Group B: Continuous monitoring
Group C: Non-continuous monitoring
Note: In the ScanTool, following selection is necessarily applicable:
"Delete readiness test for fault code"!
Here, the readiness tests from several driving cycles are displayed and the probability is highest that all
supported RCs are set to positive. When selecting "Readiness test of this cycle", the supported RCs are
usually not set to positive.
Generally, immediately before the exhaust-gas test without a wilful occasion, for example, if no drivability
complaints have been made by the customers, the fault memory should not be deleted, because this will
also delete all readiness test codes, in addition to the error codes.
Only within the scope of service review or for customer complaints, the fault memory should be viewed in
mode 3 with regard to possible repeatedly confirmed errors shortly before the exhaust-gas test. If errors exist
that would lead to a failure of the exhaust-gas test, carry out a repair and then delete the fault memory. Then 2-
3 driving cycles* should be carried out in which the readiness of the individual systems can be reset.
* = Engine start, acceleration phases, constant-speed driving, overrun phase, idle operation and stopping the
engine
Readiness tests(Readiness codes) Petrol engine:
Continuous monitoring Non-continuous monitoring

- Byte B data - - Byte C data -
0 misfire 0 Catalytic converter
1 Fuel system 1 Catalytic converter - heating
2 Components 2 Fuel tank ventilation system/EVAP
3 -Free- (if necessary O-/D monitoring) 3 Secondary air system
4 -Free- (if necessary air conditioning/refrigerant)
5 Oxygen sensor
6 Oxygen sensors heating
7 EGR and/or Valvetronic system
Table: Designations of the Readiness Codes
Manufacturer's specifications for Readiness Code - Evaluation:

In the group B "continuous Überwachung_Data byte B", all parametrised and supported RCs must be set
to positive. that is, the electrical check of the sensors/actuators has lapsed in all functions; to do this usually a
1-2 minute engine operation in idle position is sufficient. If one of these RCs is not set to positive even when
the engine is running (also referred to as "test not carried out"), then the exhaust-gas test shall be
evaluated as failed.
In the Group C, "non-continuous Überwachung_Data byte C" all, but at least 5, parametrised or
supported RCs should be checked to be positive. Few "long-time needed" RCs cannot yet be set to
positive! (also referred to as "test not carried out").
Reason: Their fault set conditions require a longer journey with different load conditions, speeds and specific
atmospheric conditions after fault memory deletion.
For BMW and MINI diesel fuel engines from exhaust emission stage EURO 6, the following 2 RCs:
Catalytic converter and secondary air may be exempted from RC evaluation, that is, not yet set to positive
or Display bit 1.
Note:
The set result by a binary indication of the individual RCs is:
0 = checked at least once or diagnosis not supported
1 = Components displayed as not yet fully checked. The figure below shows the
Readiness Codes
Continuous testing_ Byte B data- Data: Petrol and diesel-engine vehicles
out/ bit
0 Misfire Yes = 0 / No = Yes = 0 / 0

1 No = 1
1 Fuel system Yes = 0 / No = Yes = 0 / 0
1 No = 1
2 General Yes = 0 / No = Yes = 0 / 0
components 1 No = 1
3 Free- (if necessary Yes = 0 / No = Yes = 0 / 0 if parametrised; Otherwise even 1
O-D monitoring) 1 No = 1
Non-continuous tests _ Data byte C/D data:Only diesel vehicles
out/ bit
0 Catalytic converter Yes = 0 / No = Yes = 0 / 0 or 1
1 No = 1
1 Catalytic converter - Yes = 0 / No = Yes = 0 / 0
heating 1 No = 1
2 Fuel tank ventilation Yes = 0 / No = Yes = 0 / 0
system/EVAP 1 No = 1
3 Secondary air Yes = 0 / No = Yes = 0 / 0 or 1
system 1 No = 1
4 Free- (if necessary Yes = 0 / No = Yes = 0 / 0
air conditioning) 1 No = 1
5 Oxygen sensor Yes = 0 / No = Yes = 0 / 0
1 No = 1
6 Oxygen sensor Yes = 0 / No = Yes = 0 / 0
heating 1 No = 1
7 EGR/Valvetronic Yes = 0 / No = Yes = 0 / 0
1 No = 1
Graphic: Evaluation matrix of the readiness test bits
1.4 Record status of the fault memory in ScanTool mode 3*

(* = Mode 3 means storage of errors which have been confirmed over multiple driving cycles).
If standardised Powertrain codes, for example, P0 123, P2 456 or manufacturer-specific Powertrain
codes, e.g P1 789, P3 123, are stored: Test = not OK
If no Powertrain codes are stored: Test = OK
1.5 Identity check of the chassis number (VIN) according to the comparison via ScanTool Mode 9:
Read out chassis number (VIN = Vehicle Identification Number) from ScanTool Mode 9 and compare it with the
vehicle type plate:
If the VINs deviate from each other: Test = not OK
1.6 OBD final evaluation:

If the:
the RC evaluation, taking into account "long-time RCs" not relevant to the set, is positive
no errors are stored in mode 3,
the VIN comparison: Vehicle to ScanTool -Mode 9- information is identical,
then the exhaust-gas test is to be concluded as "passed".
If one of the aforementioned points is not OK, the exhaust-gas test via OBD is considered failed.
The OBD data MIL and RC status from Mode 1; Error codes from Mode 3 and VIN from Mode 9 are to be
printed on the verification certificate.
ScanTool and the vehicle-side interface (OBD socket), the emissions test is classed as “not passed” and the
vehicle is to be repaired.
2. Test scopes for exhaust-gas test on EURO 6 with petrol engine and closed-loop catalytic converter and
OBD in Germany: :
In Germany, at present, the two-stage test procedure for all vehicles of categories M (passenger cars) and
N (trucks) from the date of first registration 01.01.2006* is applicable even for EURO 6 vehicles with
obligatory exhaust-gas test operator prompting. (* = from EURO 4 / IV) In addition, the exhaust-gas test may
be performed on these vehicles from 01.06.2015 only with the operator prompting according to "Exhaust-gas
test - devices user guide 5".
2.1. Level 1 = OBD - check:

Read out and evaluate the OBD data, as described in section 1.1 - 1.6, but with the following changes:
Section 1.2 Exhaust emission classification check on EURO 6 omitted because all vehicles from first
registration 01.01.2006 (from EURO 4) are primarily checked via the OBD.
In section 1.3.3, all continuous and all non-continuous supported readiness codes must be set to
positive (bit = 0).
If the readiness codes of the OBD system operated by the engine control unit are not or not
completely set to positive, that is, the OBD system itself is not yet ready for testing, for example,
because the fault memory was deleted shortly before, a exhaust gas tailpipe measurement must be
carried out additionally according to Section 2.2.
2.2. Level 2 = Exhaust gas opacity measurement as additional check under the following precondition:
Note: The following procedure generally also applies to all petrol vehicles with closed-loop catalytic converter
before the first registration 01.01.2006. See also the BMW Service Information "Test instructions for the
exhaust-gas test on BMW vehicles with petrol engines" from 04/2012.
2.2.1 Visual inspection of emission-relevant components:

Note: This test step will be deleted from the new version of §29_StVZO in accordance with 47th amendment
regulation as from 01.07.2012, as the visual inspection is an integral part of the technical vehicle inspection and
2.2.2 Effective check using emission measurement* at the exhaust tailpipe at operating temperature, that is,
at minimum 60°C engine oil temperature.
Emissions threshold values at increased idle and idle position:
a. Increased speed in idle position°, that is, at least n = 2500 rpm and CO according to nominal data, otherwise
CO to EURO 3: max. 0.3 vol %; CO from EURO 4: max. 0.2 vol % plus Lambda determination*: min. 0.97 – max.
1.03.
b. Idle position speed according to type-specific manufacturer's specifications: CO according to exhaust gas
nominal data, otherwise CO to EURO 3: max. 0.5 vol %; CO from EURO 4: max. 0.3 vol %.
* = determined from CO, CO2, O2 and HC according to Brettschneider formula
* = engine speed range for all BMW vehicles: n = 2300 - 2700 rpm
Note: For catalytic converter conditioning reasons it is necessary both throughout the EU and in Germany to
carry out the CO and lambda measurement first at increased engine speed and only then at idle.
Graphic: Opacity characteristic during engine start-up = free acceleration
2.2.3 Oxygen sensor control circuit check:

For BMW "closed-loop catalytic converter" vehicles from first registration in around 1996, the oxygen sensor
control circuit check is carried out via the so-called "Replacement method". The oxygen sensor emissions
control check is carried out by measuring the voltage excursion for oxygen-bistable sensors or the current for
broadband oxygen sensors of control sensors installed at the catalytic converter inlet.
Measurements are made in idle position using usual diagnosis tools (for example, EOBD ScanTool integrated
in the exhaust-gas test diagnosis tester) at an adequate lambda value from 0.97 to 1.03.
BMW examples:
Sensor type bistable sensor: voltage excursion delta min. 0/3 V
Sensor type broadband oxygen sensor: current from -0.115 to + 0.077 mA
For BMW vehicles with the "Magermix" engines N43 and N53, due to large lambda range current values from: -
1.60 to + 1.82 mA apply
For detailed engine-specific information, see BMW emissions test nominal values.
72/306/EEC.
General notes:
The procedure described in this service information also applies to the BMW vehicles with petrol engines from
exhaust emission stage EURO 6 and plug-in hybrid technology, for example, BMW X5_F15-PHEV, BMW
225xe_F45-PHEV, BMW 330e_F30-PHEV and BMW i3_I01 with Range Extender or BMW i8_I12.
Note: In Germany, the operator authorised to conduct exhaust-gas test on high-voltage vehicles according to
the specifications of the employers' liability insurance association/Statutory Accident Insurance "BGI/GUV-I
8686" must have successfully completed at least one approximately 1 hour-long "Briefing on working on
intrinsically safe high voltage vehicles"
The manufacturing stage emissions test nominal values, for example, engine speed ranges; CO and oxygen
sensor limit values including their current values are shown in the BMW emissions test nominal data
acquisition related to the type.
BMW Aftersales Portal and for “third-party users”, via the Internet from the BMW web portal Technical Parts
information system: “ASAP”, module - emissions test nominal values, at the web addresses:
http://www.parts.bmwgroup.com or
Incidentally, in Germany, the new "Guidelines for conducting exhaust gas test on vehicles according to Section
6.8.2 of Enclosure VIIIa German road traffic licensing regulations (StVZO) from 30.09.2014" are applicable.
Country-specific specifications of other countries must be given priority in any case to this SI
specifications.
Enclosure 1 "ScanTool services"

Reading and display functions of the OBD - Generic ScanTools
Select scan tool connected to

OBD functions interface
Detect the EOBD or US OBD-2 Example: Society of Automotive Engineers J 1850,
diagnosis report International Organization for Standardisation 9141-2,
International Organization for Standardisation 14230-4
(= Key Word Protocol-2000 Fast), International
Organization for Standardisation 15765-4 (= CAN);
Service 01 Malfunction indicator lamp status; Listing of all supported systems/functions;
Readiness code; Number of
stored errors; call-up of current
engine data (e.g.: n-mot;
temperatures; load conditions
etc.)
Service 02 Calling-up “Freeze Frame” data to Marginal conditions in which error codes were set
stored error codes, for example,
to P0100: for n = 1,200 revolutions
per minute; Tw = 22°C; Partial
load= 10%, v = 0 km/h, etc.
Service 03 Calling-up all set error codes. g. Listing of all error codes that make the malfunction
P0100 “Air flow circuit indicator lamp light up ; Faults that are confirmed over
malfunction” multiple driving cycles
Service 04 Deleting the OBD error codes, Only permissible for test purposes after repair or if
Freeze Frame and all other data renewed driving cycle occurs
Service 05 Monitoring of oxygen sensors, for Checking the current control voltage - engine must be
example, sensor 1: 0.35 <--> 0.87 running
volts
Service 06 Call-up of the shadow fault Not continuously monitored functions, for example, only
memory, e. g. P0410 “Secondary 1 x after each engine start
air feed malfunction”
Service 07 Call-up of the shadow fault Continuous monitoring; fault codes stored here must
memory, for example, P0133 not yet lead to the lighting up of malfunction indicator
oxygen sensor 1 = slow response lamp
Service 08 System or components, for Only required for in-depth diagnosis steps in Service
example, valve actuation for fuel
tank ventilation system
Service 09 Vehicle identification (chassis for example, for documentation; as well as data for
number control units number; official field monitoring
mileage with malfunction indicator
lamp ON)
Service Display permanent error codes for example, non-deletable NOx codes
$0A
00 20 12 (866)
Test instructions for the exhaust-gas (emissions) test on BMW vehicles with diesel
engines
BMW diesel as from Series 3 / E30 and Series 5 / E28; MINI diesel as from
R50
Situation: With reference to the presentation of the basics pertaining to the exhaust emissions test
in accordance with Service Information bulletin 00 18 12 (864) of 01.04.2012 “General and
legal information on performing the periodic exhaust-gas (emissions) test”, the exact test
scopes and technical details are described for the exhaust emissions test on diesel-engine vehicles.
Vehicles concerned:BMW vehicles as from Series 3 / E30 and 5 / E28, i.e. from 03/1983, MINI diesel as
from R50
Procedure: 1. Official test scopes:
1.1 EU-wide test scopes:

Vehicle identification check: Vehicle and vehicle documents match; recording of the vehicle data for the
test certificate.
Visual inspection of the exhaust system and the emission reduction unit (e.g. exhaust gas recirculation;
oxidation catalytic converter or particulate filter) for completeness, proper condition and leak-tightness.
Setting check: Idle and maximum speeds at no lead according to manufacturer's specification < see
BMW emissions test nominal values
The effective check is performed by determining the exhaust gas opacity at the exhaust system tailpipe
during “free acceleration” at operating temperature, i.e. with engine oil temperature at minimum 60 °C with
selector lever position in “Neutral”. Free acceleration is defined as revving the engine from idle up to
maximum speed at no load in response to a swift opening of the throttle. The accelerator pedal must be
depressed quickly and continuously within max. 1 second from the idle stop to the full load stop. To
determine the actual opacity state (opacity coefficient k in m-1), it is necessary to create the arithmetical
mean from at least 3 engine revving operations.
Caution!
In few cases, under certain circumstances, it could lead to a state where the DME activates an
engine speed limitation to 2000 rpm for the reason of component protection. After the terminal
change, this protective function is automatically deactivated again.
Opacity characteristic during engine revving = “free

acceleration”
1.2 Opacity limit values:

1.2.1 Vehicles first registered as from 01.01.1980 up to and including exhaust emission stage EURO 3 or
up to date of first registration 30.09.2006:
Primarily in line with the “sticker value” specified on the vehicle type plate in accordance with EU
Directive 72/306/EEC
BMW type plate with “sticker value” 0.51 in the small rectangle.
If the sticker value is not available or cannot be applied: according to type-specific manufacturer
specifications, see BMW emissions test nominal values;
otherwise:
Naturally aspirated engines: k = max. 2.5 m-1
Turbodiesel: k = max. 3.0 m-1
1.2.2. Vehicles as from exhaust emission stage EURO 4 or no later than from date of first registration
01.10.2006:
Primarily in line with the “sticker value” specified on the vehicle type plate in accordance with EU
Directive 72/306/EEC (see previous illustration)
If not available: - Naturally aspirated and turbodiesel engines: k = max. 1.5 m-1
1.3. The EU at prescribes does not prescribe an additional test of the mandatory EOBD system for vehicles
with diesel engines.
2. Test scopes and limit values in Germany:
2.1 The test scopes for vehicles as from date of first registration 01.01.1980 up to 31.12.2005 correspond
to those as described in Point 1.1.
2.2. Visual inspection:

Note: This test step will be deleted from the new version of §29_StVZO in accordance with 47th Amendment
regulation from 01.07.2012, as the visual inspection is an integral part of the technical vehicle inspection and
2.3 The following opacity limit applies during an exhaust emissions test as from 01.07.2012 to all diesel-
engine vehicles:
the “sticker value” specified on the vehicle type plate in accordance with EU Directive 72/306/EEC
(see illustration under Point 1.2)
If the sticker value is not available or for technical reasons cannot be applied, then the following applies to
naturally aspirated and turbodiesel engines:
Vehicles first registered between 01.01.1980 and 30.09.2006: k = max. 2.0 m-1
Vehicles first registered as from 01.10.2006: k = max. 1.5 m-1
72/306/EEC.
2.4 Diesel-engine vehicles as from a date of first registration 01.01.2006, i.e. all featuring an OBD, are tested
in accordance with a 2-stage test procedure:
Engine malfunction indicator lamp (MIL)
OBD diagnosis connection
Vehicle identification check: Vehicle and vehicle documents match; recording of the vehicle data for the
test certificate.
Visual inspection of the exhaust system and all the emission reduction units for completeness, proper
condition and leak-tightness.
Note: This test step will be deleted from the new version of §29_StVZO in accordance with 47th
Amendment regulation from 01.07.2012, since this is an integral part of the technical vehicle inspection
and thus the same components are not inspected twice.
Stage 1 of test:
OBD function check: -See also Enclosure 1 ScanTool modes-
> Function and status of malfunction indicator lamp (MIL)

Engine off - MIL not lit = not OK
Engine running - MIL off = OK
Engine running - MIL lit = not OK
> Status of OBD test readiness in ScanTool mode 1:

I.e. readout and evaluation of the individual test readiness codes (RC) in the two OBD categories:
Group A: Continuous monitoring and Group B: Non-continuous monitoring.
If all the RCs operated by the engine control unit are positively set, i.e. the OBD self-test has run through
all the functions, then:
> Record status of fault memory in Mode 3 (= faults confirmed over several driving cycles):
- If standardised P codes (Powertrain codes), e.g. P0 100 or P2 230, are stored = not OK
- If no P codes are stored = OK
> OBD final evaluation: If the MIL status is OK and the RCs have run positively and no faults are stored in
Mode 3, then the emissions test can be concluded as OK.
ScanTool and the vehicle-side interface (OBD socket), the emissions test is classed as “not passed”!
2nd stage as additional test with the of following condition:

If the readiness codes of the OBD system operated by the engine control unit are not or not completely
positively set, i.e. the OBD system itself is not yet ready for testing, e.g. because the fault memory was
deleted shortly before, a opacity measurement must additionally be carried out.
Effective check by means of opacity measurement as described (methods) in Point 1.1 or 2.1:
The opacity limits correspond to the details given in Point 2.2.
3. BMW engine specifics:

1. Exhaust emissions test on diesel-engine vehicles with OBD
>> See also SI 00 06 05 (203) date 09/2005 - only applies to diesel exhaust emissions test in Germany -
Situation: The exhaust emissions test (emissions testing of diesel-engine vehicles with OBD) has since
01.10.2005 featured a new test category “Diesel with OBD”.
In addition to the previous opacity measurement now the following OBD data are read out from the engine
control unit and evaluated with the Generic ScanTool integrated in the emission tester:
Status of exhaust gas indicator lamp
Test readiness display
Fault codes
The engine data required for measurement, such as motor temperature and engine speed, no longer have to
be recorded by separate sensors, such as oil temperature sensor or speed signal or harmonic content of the
battery voltage, but instead are also adopted from the OBD data into the test program.
This test category was an intermediate step until the introduction of the general 2-stage exhaust emissions
test for all vehicles first registered as from 01.01.2006.
Vehicles concerned: E87/1 Series, E46/3 Series, E90/3 Series, E91/3 Series, E60/5 Series, E61/5
Series,E65/7 Series, E83/X3; E53/X5, MINI D
Procedure:
1. Diesel vehicles with on-board diagnosis (OBD) All BMW and MINI diesel vehicles produced for the
European market as from 01.09.2003 which are equipped with the OBD prescribed in the EU must be tested in
the new test category “Diesel with OBD”.
Note:
The diesel model X5-3.0d in the E53 only with automatic transmission and SA200 “diesel particulate
filter” is produced as from 01.10.2005 also with EURO 4 technology. Only in this version is an OBD
integrated in the DDE control unit. Consequently this model of vehicle must also be tested in the new
test category “Diesel with OBD”.
The new BMW 8-cylinder diesel models BMW 745d introduced as from 04/2005 in the E65 / model
revisions, BMW model codes HM 61 and HM 62, are equipped with an OBD within the framework of EURO
4 technology and consequently must be tested in the new test category “Diesel with OBD”.
2. Diesel-engine vehicles without on-board diagnosis (OBD)
The following BMW diesel-engine vehicles with production date after 01.09.2003 contain no OBD and must
therefore be tested in the previous test category “Diesel without OBD”. This affects:
BMW X5-3.0 d / E53 - EURO 3 with the BMW model code: FA71, FA72, FB71, FB72 or the German KBA
numbers HSN: 0005 / TSN: 679, 786, 791
Reason: Vehicle was homologated as an N1 vehicle, for which OBD was required by law only at a later
stage.
BMW 740 d / E65 - EURO 3 with the BMW model code: GM41 or German KBA numbers HSN : 0005 / SN:
747
Reason: Gross weight rating over 2500 kg. For such vehicles OBD is required by law only at a later stage.
3. General:
If in the BMW diesel-engine vehicles with OBD and before date of first registration 01.01.2006 one of the three
test readiness codes (RC) is reported by the Generic ScanTool as “not positively concluded”, this is no
reason for a “not OK evaluation” of the emissions test for these vehicles!
The status of the RCs is merely recorded in the test certificate, but not evaluated! The system tests for the
three subsystem are indeed performed by the DDE control unit, but, depending on the interpretation of the
communication protocol from the DDE control unit to the scan tool, not always correctly output.
.
Enclosure: Emissions test report on vehicles with on-board diagnosis
.
00 06 05 (203)
Testing procedure for emissions test (AU) on diesel vehicles with OBD
BMW and MINI
Situation: In Germany from 1 October 2005, the emissions test (AU) for diesel vehicles with OBD
must be carried out in a new test category
”Diesel with OBD”.
In addition to the current opacity measurement, the following OBD data will be read out from the engine control
unit and evaluated by the Generic ScanTool integrated in the emissions tester:
Exhaust gas indicator lamp status
Test readiness indicator
Fault codes
The engine data needed for the measurements, for example engine temperature and engine speed, no longer
need to be recorded by separate sensors, such as the oil temperature probe or engine speed signal (TD) or
battery voltage harmonic wave, but rather are read into the test program from the OBD data.
Affected vehicles:
E87 / 1-Series E65 / 7-Series
E46 / 3-Series E83 / X3
E90 / 3-Series E53 / X5
E60 / 5-Series MINI D
E61 / 5-Series
Procedure: 1. Diesel vehicles with On-Board Diagnosis (OBD)

All BMW and MINI diesel vehicles produced for the European market from 1 September
2003 equipped with OBD as prescribed in the EU must be tested in the new test category ”Diesel with OBD”.
Note:
The diesel model X5 3.0d in the E53, only with automatic transmission and option 200
”Diesel particulate filter”, will also be produced from 1 October 2005 with EURO 4
technology.
In this version, an OBD is integrated in the DDE control unit. As a result, these vehicles
models also have to be tested in the new test category ”Diesel with OBD”.
The new BMW 8-cylinder diesel models BMW 745d launched in 04/2005 as the E65 / MÜ,
BMW code HM 61 and HM 62 as equipped with OBD as part of the EURO 4 technology and
therefore have to be tested in the new test category ”Diesel with OBD”.
2. Diesel vehicles without On-Board Diagnosis (OBD)
The following BMW diesel vehicles with production date after 1 September 2003 do not have OBD and
therefore have to be tested in the old emissions test category ”Diesel without OBD”.
BMW X5 3.0d / E53 - EURO 3
BMW code: FA71, FA72, FB71, FB72
HSN: 0005 / TSN: 679, 786, 791
Reason: The vehicle has homologation as N1 vehicle for which OBD is not needed until later.
BMW 740d / E65 - EURO 3
BMW code: GM41
HSN: 0005 / SN: 747
Reason: Permissible gross weight greater than 2500 kg. OBD is not legally required on such vehicles until
later.
If one of the three readiness codes (RC) on BMW diesel vehicles with OBD be registered by the Generic
ScanTool as ”not positively concluded”, this is not a reason for a ”failure” in the emissions test!
The status of the RCs is merely recorded in the test certificate - it is not evaluated!
The system tests for the three subsystems are always performed by the DDE control unit, but their results are
not always communicated correctly to the ScanTool due to a differing interpretation of the communication
protocol.
00 30 11 (735)
All MINI
All Rolls-Royce
00 05 02 (848)
Discontinuation of diesel purging
M57TU, M67, M57, M51, M47TU, M47, M41, M21
Diesel purging, BMW part number 81 22 9 407 528, has been discontinued with immediate effect.
Reason:
In diesel engines with a distributor-type injection pump, this diesel purging was provided as a temporary
solution for engine rattling problems. As these problems have now been rectified, the use of fuel additives is
no longer necessary.
In diesel engines with common rail, the wear behaviour of the high pressure pump, the injectors, etc. was
influenced negatively by this purging.
Therefore the use of fuel additives, even from other manufacturers, should always be avoided.
It is recommended to use the following arguments with the customers:
Due to extremely precise production tolerances in the components of common rail systems and the
impairment of the lubricity of the fuel, it is advised to avoid the use of fuel additives.
Note:
In the event of damage, a reimbursement of any repair costs via warranty is impossible if the use
of fuel additives can be proven!
11 03 04 (156)
BMW Quality Longlife-04
All
Situation: The launch of the E90 and E87 with diesel particulate filter, makes a new engine oil BMW
Longlife-04 absolutely essential. The function of the diesel particulate filter and low fuel
consumption can only be guaranteed for the vehicle's entire service life if BMW Longlife-
04 engine oil is used.
Effect: A new type of additive in the engine oil means that less ash is formed during combustion
and thus prevents the diesel particulate filter from becoming blocked with ash deposits.
Affected vehicles:This engine oil is unambiguously specified for diesel engines with diesel particulate filter.
However, it also satisfies the requirements of spark-ignition engines. Longlife-04 engine
oil specifications include the requirements of Longlife-01 and Longlife-98.
Longlife-04 oils are only approved for spark-ignition engines in Europe (EU plus Switzerland, Norway and
Liechtenstein). They must not be used outside this area.
Procedure: For further information, please refer to BMW Operating Fluids Service Information bulletin
”Specified engine oils for BMW Group engines” (Enclosure 3) .
00 14 03 (047)
All model series
a single document.
hotspots:
E36 with M41 engine
E36, E53 from 01.01.1999
E36 up to E53 since 01.06.1999

E3 E34 E32 E31 R50 (MINI)
E30 E39 E38 E52 (Z8) R53 (MINI)
E36 E53 (X5) E65
E46 E60 E66
E67
E83 (X3)
Z1
Z3 (E36/7)
Z4 (E85)
1 / E81 - E87; 3 / E90-E93
5 / E60 - E61; 6 / E63 and E64; X3 / E83; X5 / E70, X6 / E71
Z4 / E85 and E86
MINI / R55, R56
00112801/1098
Replace EGR pipe, EGR valve and suspension element for EGR radiator
E46 / M47
Situation: In the above-mentioned vehicles, EGR pipes, valves and suspension elements were
installed which do not correspond to the factory specifications for durability.
EGR = exhaust-gas recirculation
Affected vehicles:E46/M47 Production period: Corresponding to list of vehicle identification numbers
(November 1997 to May 1998)
Measure: The EGR pipe, the EGR valve and the suspension element for the EGR radiator must be
replaced.
Procedure: 1. Remove EGR pipe and EGR valve:
Undo bolt, and remove the front acoustic

cover.
Note: Bolt (1) is not visible.
Undo bolts (1) from the EGR radiator.

Installation note: Clean sealing surfaces and replace gasket.
Note: Undo the EGR valve from the intake plenum and remove
together with the EGR pipe.
Note on installation: Check the rubber seal between the intake
plenum and the EGR valve for damage and replace, if
necessary. Tighten the profile clamp between the EGR valve
and the EGR pipe with a tightening torque of 7 Nm.
2. Replace suspension element for the EGR radiator:
Undo suspension element from the EGR radiator and at the gear case cover.
Parts:
Designation Part number
EGR parts set, consisting of: 11 71 0 000 687
- EGR valve
- Bolts for EGR valve
- EGR pipe
- Profile clamp between EGR pipe and
EGR valve
- Gasket between EGR pipe and EGR
radiator
Suspension element for EGR radiator 11 12 2 249 567
Reimbursement:Material and labour costs incurred can be claimed through the usual warranty channels
Special defect code subject to current warranty terms.
00 11 28 01 00
Replace EGR pipe, EGR valve and suspension element for EGR radiator
Job number 00 52 508
Flat rate units 5Â FRUs
Warranty type 1
Warranty level 1
00112901/1098
Replace exhaust-gas recirculation pipe and exhaust-gas recirculation valve
E46 / M47
Situation: Exhaust-gas recirculation pipes and valves have been installed on the vehicles listed
above that do not meet factory durability specifications.
EGR = Exhaust-gas recirculation
Affected vehicles:E46/M47 Production period: Corresponding to list of vehicle identification numbers
(March 1998 to October 1998)
Measure: The exhaust-gas recirculation pipe and exhaust-gas recirculation valve must be replaced.
Procedure: Remove exhaust-gas recirculation pipe and exhaust-gas recirculation valve:
Undo bolts, lift-off acoustic cover at the

front.
Note: Bolt (1) cannot be seen.
Undo bolts (1) from exhaust-gas recirculation cooler.

Installation note: Clean sealing surface, renew gasket.
Note: Undo exhaust-gas recirculation valve from intake plenum

and remove together with exhaust-gas recirculation pipe.
Installation note: Check rubber gasket between intake plenum
and exhaust-gas recirculation valve for damage. Replace if
necessary. Tighten profile clamp between exhaust-gas
recirculation valve and exhaust-gas recirculation pipe to a
tightening torque of 7 Nm.
Parts:
EGR parts set comprises: 11 71 0 000 687
- EGR valve
- Bolts for exhaust-gas recirculation valve
- EGR pipe
- Profile clamp between EGR pipe and
EGR valve
- Gasket between EGR pipe and EGR
cooler
Invoicing: Material and labour costs incurred can be claimed through the usual warranty channels
00 11 29 01 00
Replace exhaust-gas recirculation pipe and exhaust-gas recirculation valve:
Labour 3 FRUs
Warranty type 1
Warranty level 1
11 08 02 (922)
Turbocharger failure
E46 / M47TU
Complaint: Noise and smoke generated in engine compartment.
No output from engine.
Cause: Turbocharger failure. Individual turbine blades overloaded due to vibrations and centrifugal
forces.
Affected vehicles:E46/M47TU
Manufacturing period: from the start of series production up to November 2003
Procedure: In case of customer complaint, the turbocharger should be replaced as follows and the
DDE control unit reprogrammed.
Replacing exhaust turbocharger
Important:
To prevent repeat repairs, after installing a new exhaust turbocharger and before flange-mounting
the exhaust system, make sure that:
Primary and main catalytic converter are not soiled or blocked
Crankcase ventilation system (vent unit) is not coked or damaged.
Replace the exhaust turbocharger as described in the Repair Instructions.
(Do not fit the exhaust system!).
Remove the crankcase ventilation system for checking and replace if it shows signs of coking or damage.
Perform the following steps with the engine at operating temperature:
Pull vacuum hose from exhaust gas recirculation valve (EGR).
Measure air flow in accordance with test specifications
at idling speed
at approx. 3500 rpm
Make a note of the values and fit the exhaust system.
Repeat the air flow measurement in accordance with test specifications.
Compare the values from the two measurements and derive the following measures from the result:
1. Values identical
Exhaust system and crankcase ventilation system OK
2. Values not identical
Replace primary catalytic converter and main catalytic converter as necessary as described in the
Repair Instructions.
As a precaution, also replace the crankcase ventilation system.
Fit the exhaust system and reassemble the vehicle.
Reprogramming DDE control unit
Important:
Two programming sequences:
1. Automatic programming sequence
2. Programming with manual input
Note: In case of customer complaint, a service data status has been approved in parallel to
series status for various equipment specifications. This data update is only to be programmed by
manual input. This is available to the dealer organisation from DIS CD 36.
Proceed as follows during programming:
Tester specification: Input:

Encoding/programming Select
Item 5: Programming Drive Train Select
Item 5: DDE programming Select
Item 1: Exchange control unit Select
Item 1: Determine basic control unit Select
Is defective DDE still installed in vehicle? Answer question with ”No”.
Enter part number of ”basic control unit”. Enter part number >7 793 443<
Enter vehicle identification number read off and enter vehicle
identification number
Enter part number of ”programmed DDE”. Take the part numbers of the
>”programmed DDE”< according to
manufacturing period and equipment
variant from the table below and
enter.
Manufacturing period Equipment variant Part number of

”programmed
DDE”
from 09/01 until 03/03 Manual transmission (5-speed), 7 795 182
from 04/03 until 11/03 Manual transmission (6-speed), 7 795 190
from 09/03 until 11/03 Automatic transmission 7 794 292
Important:
Adaptation values still have to be cleared. To do this, switch the ignition off for at least
25 seconds.
DDE programming is complete. Continue as prompted by tester.
Parts:
Description: Part number: Quantity:
Turbocharger 11 65 7 794 144 1
Gasket 11 62 2 244 515 1
Defect code subject to current warranty terms.
11 65 90 15 00This defect code is not contained in the official
Defect Code Catalogue but has been included in the system,
thus enabling warranty claims to be processed.
In case of order without additional
repair operations:
replace turbocharger, remove and install / check
crankcase ventilation system,
check exhaust system,
program DDE.
Labour 31 FRUs
As part of a visit to the workshop:

replace turbocharger, remove and install / check
crankcase ventilation system,
check exhaust system,
program DDE.
Labour 29 FRUs
Warranty type 1
Warranty stage 1 (within vehicle warranty)

2 (outside vehicle warranty)
Only one of the above job numbers may be submitted for reimbursement.
Reimbursement is limited to 36 months / 100,000 km and only possible until November 2006.
12 01 00 (534)
Battery charge warning light flickers
E46 / M47, M57
Complaint: On the above vehicles, the battery charge warning light can intermittently flicker of light up
briefly while the vehicle is being driven.
Cause: Faults in the fault recognition logic circuits of the alternator regulator lead to intermittent
actuation of the battery charge warning light. The charge level of the vehicle is not affected
and there is no fault in the instrument cluster.
Affected E46 with M47/M57
vehicles: Manufacturing period: September 1999 to April 2000
Remedy: From April 2000, vehicles will be equipped in series production with an additional circuit
which prevents the battery charge warning light from being incorrectly actuated.
In case of customer complaint, an adapter cable must be retrofitted to the instrument
cluster.
Procedure: Remove the complete instrument cluster
(please refer to Repair Instructions for E46, job item no. 62 21 000).
Remove the connector on the right of the instrument cluster (26-pin, black).
Note:
When working with the wiring harness disconnected, take care to ensure that no electrostatic charge comes
into contact with the connectors.
Fig. 1:
Connector on instrument cluster
Install the adapter cable between the vehicle wiring harness and the instrument cluster.
Note:
The entire plug connector must be mantled in foam after assembly.
Fig. 2:
Foam mantle around plug connector
Position the plug connector between the adapter cable and the wiring harness centrally in the opening in the
air duct behind the instrument cluster.
Fig. 3:
Routing the adapter cable
Note:
When installing the instrument cluster, take care to ensure that the plug connector between the vehicle wiring
harness and the adapter cable is positioned in such a way that it will not cause any rattling noises while the
vehicle is being driven.
After installation, there must not be a gap between the instrument panel and the instrument cluster.
Parts: Adapter cable: Part no. 12 51 7 786 936
Defect code subject to current warranty terms as follows:
12 51 92 87 00
Refit adapter cable:
Labour 5 FRUs
Warranty type 1

Reimbursement is limited to 36 months/100,000 km and only possible until December 2001.
16 02 99 (501)
Introduction of new fuel filler caps for US models
E36 / Z3, , E38, E39, E46 US only
Complaint: An incorrectly sealed fuel filler cap leads to repeated incorrect warnings from the "CHECK
ENGINE" lamp in the instrument cluster. See section "Remedy": newly developed fuel filler
cap with improved sealing characteristics.
After refuelling and two or more engine cold starts, the "CHECK ENGINE" lamp lights up in the instrument
cluster. The following fault codes are stored in the DME fault memory after just one cold start following
refuelling:
M44 with DME M5.1:
- BMW fault code: 94

Description: Tank leak detected - major leak
OBD-2 code: P 0455

Description: Tank leak detected - minor leak
OBD-2 code: P 0442
M52 with DME MS 41.1:

OBD-2 code: P 0455

OBD-2 code: P 0442
M52TU with DME MS 42:

Description: Fuel system, major leak detected
OBD-2 code: P 0455

Description: Fuel system, minor leak detected
OBD-2 code: P 0442

Description: Fuel system, fine leak 0.5Â mm
OBD-2 code: P 0456
S52 with DME MS 41.2:

OBD-2 code: P 0455

OBD-2 code: P 0442

Description: Tank leak detected
OBD-2 code: P 0442
S62 with DME MSS 52:

OBD-2 code: P 0442
M73 with DME M 5.2.1:

OBD-2 code: P 0442
Explanation: Within the framework of the OBD-2 systems checks legally required in the USA, the fuel tank
system is checked for leaks after each cold start (coolant temperature less than 30 degrees Celsius). To this
end, the tank system of vehicles with OBD-2 is checked for leaks while the engine is running. If the values
measured are not reliable, as it is the case with the filler pipe open, the fuel tank system is assumed to have
developed a leak. This leads to the fault codes stated above being stored after the first start test. After the
second start test, the "CHECK ENGINE" lamp will light up.
Note: Fault messages "major/minor leak" may also have other causes. Only the description "major leak"
indicates an inadequately sealed fuel filler cap.
Cause: Inadequately sealed fuel filler cap:
1. Result of insufficient sealing pressure at too small a closing angle. The fuel filler cap is
often not turned to the stop.
2. Retaining strap on fuel filler cap caught between the filler pipe and the fuel filler cap.
See Figure 1.
3. Refuelling with the engine running.
Figure 1: Retaining strap on fuel filler cap

1 Retaining strap
2 Filler pipe
3 Fuel filler cap

Affected vehicles:E36/Z3, E38, E39, E46, US versions only
Manufacturing period:
E36/Z3 US from 07/1999

E38 US from 01/2000
E39 US from 06/1999
E39/2 US from 08/1998
E46 US from 07/1999
Remedy: Between 08/1998 and 01/2000, depending on model series, newly developed fuel filler
caps (see Fig. 2) with improved sealing characteristics were introduced. The force required
has been significantly reduced and the sealing effect and the acknowledgment "closing
procedure complete" have been improved. Despite this, the fuel filler cap must always be turned until it is
heard to have reached the stop.
Note: The fuel filler cap and the filler pipe form a single unit. The modified fuel filler cap cannot be retrofitted
individually.
Figure 2: Closing angle for the newly developed fuel filler caps
A Alignment range and free play = approx. 40 degrees
B Closing range = approx. 80 degrees
C Range of audible clicking noise = approx. 10 degrees
Note: The fuel filler cap will spring back, the clicking noise can be repeated at will.
Complete closing angle = approx. 130 degrees
Procedure:
1. Customer information:
Do not refuel the vehicle with the engine running, not even to keep the vehicle's air conditioner operating!
Important:
Refuelling with the engine running is prohibited in all countries due to the potential risk of fire in the area of
the filling station!
2. Follow the correct procedure to refit and seal the fuel filler cap properly. Make sure that the retaining strap
is properly positioned.
Please refer to enclosed customer information bulletin.
3. Following any maintenance work, repairs or checks on the vehicle (incl. the delivery inspection), the
following procedure should be followed:
a) Read out the DME control unit fault memory.
b) If the BMW fault codes ("Tank leak detected") are displayed, carry out the function check "Tank leak -
system check" via DIS.
c) Check that the fuel filler cap is correctly seated and correct if necessary. When doing this, make sure
that the retaining strap does not get caught.
d) Rectify any other faults which may be stored (besides the fault codes given).
e) Clear the fault code memory.
f) Attach the sticker to the fuel filler cap as necessary.
Sticker on upper section of fuel filler cap
Sticker on lower section of fuel filler cap
Parts: As required:
Sticker for upper section of fuel filler cap Part number 71 21 1 184 663
Sticker for lower section of fuel filler cap Part number 71 24 6 750 683
Packing unit: qty. 50
Reimbursement:Warranty reimbursement is not possible for customer information. This is primarily a
consultation or reminder of the correct procedure to be followed. Please refer to Owner's
Handbook.
The situation described in this Service Information bulletin, including the customer information bulletin,
should be made available to all sales staff with the request that customers are informed right from the
vehicle handover.
Defect code none
Job number none
Labour none
00 14 03 (047)
All model series
a single document.
hotspots:
E36 with M41 engine
E36, E53 from 01.01.1999
E36 up to E53 since 01.06.1999

E3 E34 E32 E31 R50 (MINI)
E30 E39 E38 E52 (Z8) R53 (MINI)
E36 E53 (X5) E65
E46 E60 E66
E67
E83 (X3)
Z1
Z3 (E36/7)
Z4 (E85)
1 / E81 - E87; 3 / E90-E93
5 / E60 - E61; 6 / E63 and E64; X3 / E83; X5 / E70, X6 / E71
Z4 / E85 and E86
MINI / R55, R56
12 02 00 (584)
Service interval display cannot be reset
E46 / M47, M57 / 320d, 330d
Complaint: The service interval display cannot be reset after an engine oil service or inspection.
Cause: The affected vehicles had an adapter cable installed on the instrument cluster as
instructed by Service Information bulletin 12 01 00 (534) which suppresses incorrect
actuation of battery charge warning light while the vehicle is being driven. This adapter
cable is missing the connection to pin 18.
Affected vehicles:E46 with M47/M57
Manufacturing period: September 1999 to February 2000
Remedy: Exchange of faulty wiring harness adapter.
Procedure: Replacing wiring harness adapter, please refer to Service Information bulletin
12 01 00 (534).
Note:
The pin allocation of the adapter cables in the parts stores has been corrected. The new wiring harness can be
identified by a green mark on the part designation label (see Fig. 1).
Fig. 1:
Colour marking on new adapter cable.
Parts: Adapter cable, part no. 12 51 7 786 936
Replace adapter cable:
Labour 4 FRUs
Warranty type 1

13 01 01 (690)
Hot-film air mass meter (HFM)
E38, E39, E46 / with M47, M57
Situation: 1. In the BMW dealer organisation, the hot-film air mass meter is often replaced
unnecessarily on vehicles with M47 or M57 engine
The diagnosis procedures for finding the cause of a customer's claim regarding the
response of the engine and the vehicle's performance are often only used if the replacement of the HFM
has not resulted in the complaint being rectified.
2. Since November 2001, the BMW Parts Service has only supplied the air mass meter version fitted to
vehicles with M57 engine from January 2001 and on vehicles with M47 engine from September 2001.
This means a revised procedure for retrofitting.
Affected vehicles:E38, E39, E46 with M47 or M57 engine
Procedure: In case of customer complaint, the DDE fault memory should first be read
Note:
Hot-film air mass meters sent in through warranty/goodwill can only be processed in conjunction
with the diagnosis report.
In countries where return is not obligatory, the diagnosis report should be filed in the vehicle
records for reliable auditing.
Proceed as follows if the fault memory entries or the nature of the complaint indicate an HFM malfunction:
A. M47 engine with DDE 3.0

With the DIS tester, work through test module ”air mass meter”.
Note:
The test module can be found in the function selection on the DIS tester under
=> Complete vehicle
=> Drive
=> DDE 3.0 engine management
=> Air supply
=> Air mass meter
The air mass meter must only be replaced if the nominal values specified in the test module ”air mass meter”
are not achieved and an instruction is given to replace the HFM.
With the DIS tester, work through test module ”air-mass system test”.
Note:
=> Complete vehicle
=> Drive
=> Air-mass system test
In the air-mass system test, the cause of the fault in the air-mass system is isolated clearly to the defective
component group and the test module for the component group concerned is automatically drawn into the
testing schedule for working through.
The HFM is then only to be replaced if an appropriate instruction to replace the HFM is given in the test module
”Air-mass system test”.
The following applies to both engines:
On no account should just the sensor element in the housing be converted. The position of the sensor
element is assigned to the housing and cannot be set in service!
Important:
Before programming, it must be noted that programming may abort on the E38 and E39 under the
following conditions:
1. Programming abort on vehicles with DSC III (E38 and E39 from date of manufacture
September 1998 to December 1999)
2. Programming abort on vehicles without DSC III
The cause of a program abort could be the ignition being switched off during programming, by the
connection between DIS/MoDiC III and the control unit being broken or by the system voltage
dropping below approx. 9 volts.
The functionality of the control units with FLASH technology are designed such that programming
can be repeated following a program abort.
In During the programming procedure, the DSC III control unit interferes with telegram traffic
case between the control unit being programmed and the DIS/MoDiC III.
1:
In The control unit being programmed refuses to communicate with the DIS/MoDiC III
case because of interference on the diagnosis cable.
2:
Always connect up a battery charger before programming as a measure against a programming
abort. Never connect or disconnect the charger during programming.
The vehicle voltage must not drop below approx. 9 volts during programming.
In Programming can only be correctly performed if the DSC III control unit is rendered free of
case current throughout programming. This is done by pulling the following fuse:
1:
E38: fuse 17 (engine compartment)
E39: fuse 31 (glove compartment)
In If programming is aborted and the situation is not described under 1 above, the control
case unit should be disconnected for approx. 1 minute.
2: After this, reconnect, switch on the ignition and perform programming again.
The most recent version of the air mass meter (part number 13 62 7 787 076) can be recognised by the
protective grille for deflecting particles of dirt and moisture (see illustration 1).
Illustration 1:
Most recent version of air mass meter.
This version can be retrofitted on all E38, E39 and E46 vehicles with M57 engine and on all E39 and E46
vehicles with M47 engine, providing the current DDE data status is programmed with the installation.
Note:
The part number of the programmed control unit must be entered manually.
Note:
If programming is not performed, the DDE control unit will misinterpret the air-mass signals,
affecting the engine's power output and exhaust emission characteristics.
When reprogramming the DDE control unit, proceed in the same way as when renewing the control unit, even
though the existing control unit is not being replaced:
1. Identify and print out the DDE control unit using
=> Diagnosis
=> Control unit functions.
Identification of the control unit is purely for reading off the part number of the basic control unit and of
the control unit to be programmed.
2. The control unit can now be reprogrammed using
=> Programming
=> DDE programming
=> Replace control unit.
3. The following prompt appears in the DIS tester:
=> ”First determine basic control unit”.
4. Answer the question
=>”Is the defective control unit still installed in the vehicle?”
with ”No”.
5. Enter the part number of the basic control unit from the control unit identification.
6. Enter vehicle identification number.
7. Enter the new part number of programmed control unit.
This part number can be found in various enclosures according to model series, engine and transmission
versions (please refer to Enclosures 1 to 9):
Find the old part number of the programmed control unit read out from the control unit identification
in the appropriate table (column ”Old part number”) and read off the new part number of the
programmed control unit (column ”New part number”).
8. Perform automatic programming and then a DDE/EWS calibration.
9. Perform ”DDE control unit identification” again and check whether the new part number of the
programmed control unit has been taken over.
Enclosure 1: E46, M47 with manual transmission
Enclosure 2: E46, M47 with automatic transmission
Enclosure 3: E39, M47
Enclosure 6: E39, M57 D25
Enclosure 7: E39, M57 D30 with manual transmission
Enclosure 8: E39, M57 D30 with automatic transmission
Parts:
Description: Part number:
HFM for
M47 and M57 engines 13 62 7 787 076
13 01 05 (182)
Checking injectors
E46, E53, E60, E61, E65, E83 / M47TU, M57TU, M67
Situation: Note:
This Service Information bulletin is valid worldwide, except
in the following markets
- USA - Spain
- Canada - Belgium
- China - Italy
- Germany - UK
- France
Damaged parts analysis on injectors from diesel engines M47TU, M57TU and M67 that have been exchanged
during warranty repairs indicates that a very high proportion of these parts show absolutely no component-
specific quality defect.
Affected vehicles:E46, E53, E60, E61, E65, E83
Manufacturing period: from April 2004
Action: If the injectors are suspected of being the cause of a customer complaint, e.g. ”engine
does not start”, they must be checked with the BMW diagnosis system DDE 5 before
being replaced.
Procedure: To test the injectors, connect up DISplus or Group Tester One (GT1) and select the
following setting:
”Function selection” > ”Complete vehicle” > ”Drive” > ”Diesel electronic system” > ”Rail
pressure control system test”
1. Start the test module and confirm the test steps as follows:
Test step / question Confirmation

Is the fuel tank empty or has the vehicle been driven until the fuel No
tank was empty?
Check pre-delivery pressure. All OK? Yes
High-pressure system free of external leaks? Yes
Check rail pressure with ignition ON. Yes
Comparison nominal/actual value OK?
Can engine be started? No
Check rail pressure at starter motor speed. No
Was nominal value achieved?
Does engine start with rail pressure sensor disconnected? No
2. Check individual injectors by measuring return quantity as per instructions from DISplus or GT1.
Collect the return quantity from the injectors in a suitable container and turn the engine with the starter motor.
Note:
The fuel return quantity from new injectors is very small (approx. 1-2 ccm per minute for each
injector).
Injectors with a return greater than 10 ccm per minute are defective and must be replaced.
Important:
If an injector is diagnosed as defective using this method, only the injector concerned is to be
replaced as per Repair Instructions. Replacing all injectors is not justified.
Please refer to Commercial Service Data (KSD)
(Please certify component causing damage)
Without additional repair order:
Check injectors.
Labour 13 FRUs for E46 with M47TU

14 FRUs for E46 with M57TU
21 FRUs for E65 with M67
Within the scope of a visit to the workshop:
Check injectors.
Labour 11 FRUs for E46 with M47TU

19 FRUs for E65 with M67
13 03 01 (761)
DDE fault-memory entry: 4A93 ”CAN message monitoring ASC3”
E46 / M47TU
Complaint: On all E46 vehicles with M47TU engine without option 210 (DSC3), the DDE fault memory
will contain the fault entry:
4A93 ”CAN message monitoring ASC3”.
Cause: All vehicles are programmed with DDE data status for option 210, DSC3.
Affected All E46 with M47TU without option 210.

vehicles: Manufacturing period: start of series production until November 2001
Procedure: On vehicles without option 210, DSC3, the fault-memory entry must be ignored.
There is neither a fault display in the instrument cluster nor any form of functional
restriction while driving.
Note:
Unnecessary troubleshooting conducted in this regard will not be reimbursed through warranty.
00 05 02 (848)
Discontinuation of diesel purging
M57TU, M67, M57, M51, M47TU, M47, M41, M21
Diesel purging, BMW part number 81 22 9 407 528, has been discontinued with immediate effect.
Reason:
In diesel engines with a distributor-type injection pump, this diesel purging was provided as a temporary
solution for engine rattling problems. As these problems have now been rectified, the use of fuel additives is
no longer necessary.
In diesel engines with common rail, the wear behaviour of the high pressure pump, the injectors, etc. was
influenced negatively by this purging.
Therefore the use of fuel additives, even from other manufacturers, should always be avoided.
It is recommended to use the following arguments with the customers:
Due to extremely precise production tolerances in the components of common rail systems and the
impairment of the lubricity of the fuel, it is advised to avoid the use of fuel additives.
Note:
In the event of damage, a reimbursement of any repair costs via warranty is impossible if the use
of fuel additives can be proven!
13 01 01 (690)
Hot-film air mass meter (HFM)
E38, E39, E46 / with M47, M57
Situation: 1. In the BMW dealer organisation, the hot-film air mass meter is often replaced
unnecessarily on vehicles with M47 or M57 engine
The diagnosis procedures for finding the cause of a customer's claim regarding the
response of the engine and the vehicle's performance are often only used if the replacement of the HFM
has not resulted in the complaint being rectified.
2. Since November 2001, the BMW Parts Service has only supplied the air mass meter version fitted to
vehicles with M57 engine from January 2001 and on vehicles with M47 engine from September 2001.
This means a revised procedure for retrofitting.
Affected vehicles:E38, E39, E46 with M47 or M57 engine
Procedure: In case of customer complaint, the DDE fault memory should first be read
Note:
Hot-film air mass meters sent in through warranty/goodwill can only be processed in conjunction
with the diagnosis report.
In countries where return is not obligatory, the diagnosis report should be filed in the vehicle
records for reliable auditing.
Proceed as follows if the fault memory entries or the nature of the complaint indicate an HFM malfunction:

With the DIS tester, work through test module ”air mass meter”.
Note:
=> Complete vehicle
=> Drive
=> Air supply
=> Air mass meter
The air mass meter must only be replaced if the nominal values specified in the test module ”air mass meter”
are not achieved and an instruction is given to replace the HFM.
With the DIS tester, work through test module ”air-mass system test”.
Note:
=> Complete vehicle
=> Drive
=> Air-mass system test
In the air-mass system test, the cause of the fault in the air-mass system is isolated clearly to the defective
component group and the test module for the component group concerned is automatically drawn into the
testing schedule for working through.
The HFM is then only to be replaced if an appropriate instruction to replace the HFM is given in the test module
”Air-mass system test”.
The following applies to both engines:
On no account should just the sensor element in the housing be converted. The position of the sensor
element is assigned to the housing and cannot be set in service!
Important:
Before programming, it must be noted that programming may abort on the E38 and E39 under the
following conditions:
1. Programming abort on vehicles with DSC III (E38 and E39 from date of manufacture
September 1998 to December 1999)
2. Programming abort on vehicles without DSC III
The cause of a program abort could be the ignition being switched off during programming, by the
connection between DIS/MoDiC III and the control unit being broken or by the system voltage
dropping below approx. 9 volts.
The functionality of the control units with FLASH technology are designed such that programming
can be repeated following a program abort.
In During the programming procedure, the DSC III control unit interferes with telegram traffic
case between the control unit being programmed and the DIS/MoDiC III.
1:
In The control unit being programmed refuses to communicate with the DIS/MoDiC III
case because of interference on the diagnosis cable.
2:
Always connect up a battery charger before programming as a measure against a programming
abort. Never connect or disconnect the charger during programming.
The vehicle voltage must not drop below approx. 9 volts during programming.
In Programming can only be correctly performed if the DSC III control unit is rendered free of
case current throughout programming. This is done by pulling the following fuse:
1:
E38: fuse 17 (engine compartment)
E39: fuse 31 (glove compartment)
In If programming is aborted and the situation is not described under 1 above, the control
case unit should be disconnected for approx. 1 minute.
2: After this, reconnect, switch on the ignition and perform programming again.
The most recent version of the air mass meter (part number 13 62 7 787 076) can be recognised by the
protective grille for deflecting particles of dirt and moisture (see illustration 1).
Illustration 1:
Most recent version of air mass meter.
This version can be retrofitted on all E38, E39 and E46 vehicles with M57 engine and on all E39 and E46
vehicles with M47 engine, providing the current DDE data status is programmed with the installation.
Note:
The part number of the programmed control unit must be entered manually.
Note:
If programming is not performed, the DDE control unit will misinterpret the air-mass signals,
affecting the engine's power output and exhaust emission characteristics.
When reprogramming the DDE control unit, proceed in the same way as when renewing the control unit, even
though the existing control unit is not being replaced:
1. Identify and print out the DDE control unit using
=> Diagnosis
=> Control unit functions.
Identification of the control unit is purely for reading off the part number of the basic control unit and of
the control unit to be programmed.
2. The control unit can now be reprogrammed using
=> Programming
=> DDE programming
=> Replace control unit.
3. The following prompt appears in the DIS tester:
=> ”First determine basic control unit”.
4. Answer the question
=>”Is the defective control unit still installed in the vehicle?”
with ”No”.
5. Enter the part number of the basic control unit from the control unit identification.
6. Enter vehicle identification number.
7. Enter the new part number of programmed control unit.
This part number can be found in various enclosures according to model series, engine and transmission
versions (please refer to Enclosures 1 to 9):
Find the old part number of the programmed control unit read out from the control unit identification
in the appropriate table (column ”Old part number”) and read off the new part number of the
programmed control unit (column ”New part number”).
8. Perform automatic programming and then a DDE/EWS calibration.
9. Perform ”DDE control unit identification” again and check whether the new part number of the
programmed control unit has been taken over.
Enclosure 6: E39, M57 D25
Enclosure 7: E39, M57 D30 with manual transmission
Enclosure 8: E39, M57 D30 with automatic transmission
Parts:
Description: Part number:
HFM for
M47 and M57 engines 13 62 7 787 076
00 14 03 (047)
All model series
a single document.
hotspots:
E36 with M41 engine
E36, E53 from 01.01.1999
E36 up to E53 since 01.06.1999

E3 E34 E32 E31 R50 (MINI)
E30 E39 E38 E52 (Z8) R53 (MINI)
E36 E53 (X5) E65
E46 E60 E66
E67
E83 (X3)
Z1
Z3 (E36/7)
Z4 (E85)
1 / E81 - E87; 3 / E90-E93
5 / E60 - E61; 6 / E63 and E64; X3 / E83; X5 / E70, X6 / E71
Z4 / E85 and E86
MINI / R55, R56
13 02 01 (745)
Service function ”Injector volume compensation”
E46 / M47TU
Situation: With the introduction of common rail technology on the M47TU engine, the new DDE 5
allows a cylinder-selective injector volume compensation. On this engine, this results in a
further improvement in the exhaust emissions levels.
The injector compensation value is determined by the manufacturer and printed on the top of each injector as
an individual 6-digit letter/number code (please refer to Fig. 1)
During vehicle production, the compensation values of the injectors are allocated to the appropriate cylinder
and stored in the DDE control unit.
In service, injector volume compensation is only necessary after the DDE control unit has been replaced or
individual (or all) injectors have been exchanged.
Affected All E46 vehicles with M47TU
vehicles:
Procedure: A. In case of control unit replacement
Until DIS CD 28 is issued (approx. December 2001), compensation values will have to be
read off from the injectors and manually entered into the new control unit via the service
function ”Injector volume compensation”. To do this, it is necessary to remove the acoustic cover from the
cylinder head and from the lower section of microfilter housing.
From DIS CD 28, the injector volume compensation values in ”old control units” that are still capable of
communications will be read off as part of the familiar programming procedure, together with the vehicle
identification, and then transferred to the new control unit.
B. In case of injector replacement
If injectors are replaced or rearranged, an injector volume compensation must be performed.
The service function ”injector volume compensation” can be found in the DIS Tester under
=> Function selection => Service functions => Drive
=> Digital diesel electronics => Calibration => Injector volume compensation
=> Test plan => Injector volume compensation
The service function first shows the compensation values stored for each cylinder.
Using the selection ”Enter new compensation values”, the cylinder whose injector has been replaced must be
entered. The compensation value can be read off from the affected injector and entered.
Repeat this procedure until all new compensation values for each cylinder have been entered.
When the service function is ended, the compensation values are stored in the control unit.
Fig. 1
Volume compensation value marking on injector:
6-digit letter/number code
Note:
If individual injectors are replaced, it is only necessary to
enter the affected compensation values.
16 01 06 (250)
Accidental refuelling with petrol
All diesel vehicles
Situation: Vehicle has been accidentally refuelled with petrol.
Petrol does not have any lubricity. Consequently, operating the common rail system with
petrol will cause considerable damage to the entire fuel system.
Vehicles concerned:All diesel vehicles with common rail system
Procedure: Where accidental refuelling with petrol is concerned, 4 scenarios are envisaged which
should be responded to as follows:
Case 1: Vehicle has not been started (according to the customer)

Drain the fuel tank completely. Check the surge tank in the fuel tank for magnetic swarf (with a magnet). If
magnetic swarf (not abraded brass particles) is present in the fuel tank, proceed as described in Case 2.
Note!
Very fine abraded brass particles in the fuel tank originate either from the fuel level sensor or the fuel
pump. However, they do not affect the service life of the components.
If there is no magnetic swarf in the fuel tank, fill the intake side of the fuel tank with 5 litres of diesel fuel.
Then re-install the fuel level sensors. Flush the fuel system thoroughly with diesel fuel as far as the high
pressure pump (feed line and return line). This ensures that petrol cannot get into the high pressure pump or
the high-pressure fuel system.
To do this, activate the fuel pump by using the control unit function in the diagnosis system for the fuel system.
Note!
If the customer states that the ignition has not been switched on since refuelling with the wrong fuel,
then draining the fuel tank completely is sufficient (provided that there is no magnetic swarf present).
Case 2: Vehicle has been started and driven (e.g. after refuelling at the filling station)
Drain the fuel tank completely. Check the surge tank in the fuel tank for magnetic swarf (with a magnet). The
strainer of the fuel quantity control valve in the high pressure pump and the strainer of the rail pressure
regulating valve must be removed and also checked for magnetic swarf.
Note!
By checking the fuel quantity control valve and the rail pressure regulating valve, it is possible to
ascertain relatively quickly and with minimal effort whether swarf is already present in the fuel system.
If no magnetic swarf is found in the fuel system, proceed with draining and flushing the fuel system as
described in Case 1. In this case, the high pressure pump must be renewed as well as the fuel filter.
Then the vehicle must be filled up with fresh diesel fuel.
If magnetic swarf is present in the fuel system, proceed as described in Case 3.
Case 3: Vehicle has been driven, magnetic swarf in the system

The entire fuel system, including the fuel tank, must be renewed. Only the rigid feed and return lines can remain
in the vehicle (flush through in the opposite direction to the direction of flow of the fuel).
The cone of the high pressure pump must be checked for friction seizure. If early signs of seizure are evident,
the engine timing must be checked. Then the vehicle must be filled up with fresh diesel fuel.
If the extent of the damage is greater than expected, proceed as described in Case 4.
Case 4: Vehicle has been driven, high pressure pump has seized up, camshafts fractured, timing chain(s)
broken.
The cone of the high pressure pump must be checked for friction seizure. If there are visible traces on the
cone, the lower chain and the sprocket of the high pressure pump must be replaced.
If the camshafts cannot be turned, a damage analysis of the engine mechanics on the cylinder head must be
carried out (lower chain broken, rocker arm fractured, camshaft fractured, piston damaged, etc.).
If the rocker arms are fractured, they must be renewed and the oil circuit cleaned.
Attention!
Search for and remove from the oil circuit all needles of the faulty bearings on the older design rocker
arms. Do not forget the oil pump.
If the camshafts are fractured, the cylinder head, together with all destroyed mounted parts, both chains and
the sprocket of the high pressure pump must be renewed. In this case, you should check whether an
exchange engine would be a cost-neutral option (for the customer). Or even whether it is more cost-effective
than repairing the engine.
The entire fuel system, including the fuel tank, must be renewed. Only the rigid feed and return lines remain in
the vehicle (flush through in the opposite direction to the direction of flow of the fuel).
Then the vehicle must be filled up with fresh diesel fuel.
Attention!
It must be pointed out to the customer that if a repair is carried out which deviates from this measure,
then warranty claims ensuing from any subsequent damage will not be acknowledged.
The cost of repairing subsequent damage resulting from incorrect refuelling will not be borne by the
warranty.
If the customer insists on a repair which deviates from this measure, the vehicle data must be
transferred to BMW AG via PuMA.
Special notice regarding bacterial contamination of the fuel system - also known as the "diesel bug"
On very rare occasions, (predominantly) in coastal regions due to the higher air humidity, the fuel system may
suffer from a bacterial contamination - also known as the "diesel bug".
This causes the fuel to become a jelly-like mass which clogs the fuel filters.
It can initially lead to a lack of power and ultimately to the engine stopping altogether.
As in Case 1, this requires the fuel system to be drained and flushed. The fuel filter must also be renewed in
this case. Then the vehicle must be filled up with fresh diesel fuel.
If the fault reoccurs, a PuMA case together with explanatory images must be created and the National Sales
Company contacted.
16 01 02 (890)
Diagnosis of fuel tank systems with fuel tank leak diagnosis module (DMTL)
All US models
Situation: Since model year 1994, all US models have been equipped with a diagnosis-compatible
system that checks the fuel supply system for leaks.
A leaking fuel supply system causes increased pollutant emissions and, according to
American legislation, must be repaired immediately. The ”Service Engine Soon” indicator lamp lights up to alert
the driver.
Systems for leak detection are tank systems with leak diagnosis pump (LDP) and fuel tank leak diagnosis
module (DMTL). These differ principally in the details listed in Table 1.
LDP DMTL
Diaphragm pump Vane pump
Vacuum line necessary for operation of Compression system
the diaphragm
Leak detection from ∅ 1 mm Leak detection from ∅ 0,5 mm
Leak detection at fuel tank by means of Leak detection at fuel tank via test module
external pressure application and/or service function
Figure 1: Block diagram of leak check
A Pressurised components 10 DME control module

1 Tank 11 Fuel evaporation control valve
2 Fuel pump 12 Feed line
3 Expansion tank 13 Return line
4 Activated carbon filter 14 Solenoid valve in DMTL
5 Fuel filter with pressure regulator 15 Dust filter
6 Injection rail 16 Charge/vent line
7 Intake manifold 17 Fuel tank vent line I
8 Fuel filler cap 18 Fuel tank vent line II
9 LDP / DMTL 19 Fuel tank vent line III
1. Leakage test with leak-diagnosis pump (LDP)
US vehicles have an AKF cutoff valve and a tank pressure sensor that are used by the tank vent system
diagnosis to enable the DME control unit to detect leaks > 1 mm in the tank and tank vent system.
With this system, a vacuum is formed and used to detect a leak. From Model Year 1998 (US 05.97), the
vacuum system was replaced by a compression system.
The depression or compression is generated by a leak diagnosis pump bolted to the activated charcoal filter
and is approx. 25 hPa. Leak diagnosis takes approx. 100 seconds, depending on the individual vehicle and is
performed after nearly every cold start. The air filter at the LDP inlet is also new.
Note:
If this filter becomes extremely soiled, you may encounter problems when refuelling the vehicle.
Diagnosis is guaranteed on the complete system (fuel circuit, leak diagnosis pump and reed
contact).
1.1 Function description of pressure-leak diagnosis
When the DME control unit performs leak diagnosis, the DME control unit actuates the solenoid valve in the
LDP unit. The intake manifold vacuum not reaches the level of the upper pump chamber (6, Fig. 2) and pulls the
diaphragm (7, Fig. 2) up against the springs (3, Fig. 2).
Figure 2: Leak-diagnosis pump (LDP)
1 Vacuum valve 8 Connection to atmosphere via

filter
2 Connection to intake manifold 9 Open/closed valve (mechanical)
vacuum
3 Spring 10 Intake valve
4 Connection to activated charcoal 11 Pressure valve
filter
5 Reed contact 12 Solenoid valve coil
6 Upper pump chamber 13 Electrical connections
7 Diaphragm
When the diaphragm (7, Fig. 2) is pulled up, a suction or pump effect is created under the diaphragm.
Suction/pressure valves allow the oscillations of the diaphragm to create a pressure of approx. 25 hPa in the
tank vent system, through the activated charcoal filter to the fuel filler cap. The oscillations of the diaphragm,
i.e. the frequency, is measured by the reed contact (5, Fig. 2). The principle of pressure leakage diagnosis is
based on a measurement of the repumping frequency needed by the leak diagnosis pump:
Repumping frequency greater than nominal value: System leaking
Repumping frequency less than nominal value: System not leaking
2nd leakage check in OBD II (on-board diagnosis) with fuel tank leak diagnosis module (DMTL)
This test procedure is able to detect leaks as small as > 0.5 mm in the fuel supply system. It thus constitutes a
significant improvement in terms of protecting the environment.
Start criterion Start condition
Engine OFF
Last engine standstill >5h
Duration of current journey > 10 min
Fuel level > 15 % and < 85 %
Ambient temperature > 4 °C and < 35 °C
Altitude above mean sea level < 2500 m
Battery voltage > 11.0 V and < 14.5 V
Table 2: Start conditions for diagnosis
2.1 Function description of fuel tank leak diagnosis module check
Once all start conditions listed in Table 2 are satisfied, the DMTL will automatically start a tank leak
measurement (OBD diagnosis).
The actual tank leak measurement comprises two phases: reference leak measurement and tank leak
measurement.
2.1.1 Reference leak measurement
During the reference leak measurement, the vane pump blows air through the so-called reference leak
( ∅ 0.5 mm).
The power intake of the pump is measured and serves as the reference current during subsequent leak
diagnosis. The strength of this pump current is approx. 20 mA to 30 mA.
This initial procedure takes place within the DMTL only and no other parts are affected. This phase serves as a
self-test for the DMTL.
If the current for the reference leak measurement is outside a certain tolerance, the DMTL will be detected as
faulty and the fault memory entry shown in Table 3 will be stored in the DME as an internal DMTL fault.
DME variant Manufacturer Fault in plain text

MS43 Siemens 142 ”Module fault DMTL”
MS45 Siemens 27CD ”Module fault DMTL”
MSV70 Siemens 2A17 ”DMTL system fault”
MSV80 Siemens 2A17 ”DMTL system fault”
MSD80 Siemens 2A17 ”DMTL system fault”
ME9.2.2 Bosch 2A17 ”DMTL system fault”
MED9.2.2 Bosch 2A17 ”DMTL system fault”
ME9.2.3 Bosch 2A17 ”DMTL system fault”
MSS65 Siemens / BMW 2776 ”DMTL pump”
Table 3: Internal DMTL fault during reference leak measurement

2.1.2 Tank leak measurement
Fig. 1 shows the components of the fuel supply system, to which pressure is applied.
Pressure is applied to the components of the fuel supply system during the tank leak measurement
procedure.
The internal solenoid valve in the DMTL (14, Fig. 1) closes the line to the atmosphere
The DMTL pump is activated
As a result, the fuel supply system is now a closed system (from the DMTL valve up to the fuel evaporation
control valve) and the pressure is increased in the entire fuel system.
During the tank leak measurement,the pump's current draw is measured. An algorithm in the DME control unit
compares the power intake of the reference leak measurement and of the tank leak measurement.
If the current draw during the tank leak measurement is lower that that recorded during the reference leak
measurement, the fuel supply system is detected as free of leaks. A leak of > 0.5 mm must be present for the
DME to store a fault.
DME variant Minor leak error Major leak error

(engine) > 0.5 mm > 1,0 mm
(fault in plain text) (fault in plain text)
MS43 8F ”Fuel tank leak diagnosis with DMTL”

MS45 27CC ”DMTL: leak
MSV70 2A16 ”Extremely minor 2A15 ”Minor leak”
leak”
MSV80 2A16 ”Extremely minor 2A15 ”Minor leak”
leak”
MSD80 2A16 ”Extremely minor 2A15 ”Minor leak”
leak”
ME9.2.2 2A16 ”Extremely minor 2A15 ”Minor leak”
leak”
MED9.2.2 2A16 ”Extremely minor 2A15 ”Minor leak”
leak”
ME9.2.3 2A16 ”Extremely minor 2A15 ”Minor leak”
leak”
MSS65 27C3 ”DMTL leak 2779 ”DMTL leak
detection” detection”
Table 4: Fault in tank leak measurement

Note:
Diagnosis will be interrupted if you start refuelling while diagnosis is in progress.
If the faults listed in Tables 2 and 3 are diagnosed twice in succession, an entry will be stored in
the DME. The ”Service Engine Soon” indicator light comes on, prompting the customer to drive to
a workshop for diagnosis and leak detection.
A fault relating to fuel tank leak detection very often occurs in connection with the fuel filler cap not fitted or
closed correctly.
The so-called ”Check Filler Cap” or ”Check Gas Cap” function has been introduced to prompt the customer
to check the fuel filler cap.
3. Check Filler Cap / Check Gas Cap function
The Check Filler Cap / Check Gas Cap function is a prompt to the driver in the event that the fuel filler cap was
not replace or closed properly after refuelling.
This function usually runs after every refuelling and gives a warning message in the instrument cluster. This
gives the driver the opportunity to close the fuel filler cap correctly before the system starts a leak check.
The key difference between this function and the OBD II leak check is that with the CFC / CGC, the MIL
indicator light (or ”Service Engine Soon” indicator light) is not actuated.
Figure 3:
”Check Filler Cap” indicator lamp.
Phase-in September 2001
Figure 4:
”Check Filler Cap I” indicator lamp.
Figure 5:
”Check filler cap II” indicator lamp.
Procedure: Case 1. Internal DMTL fault (see Table 3)

Proceed as follows if such an internal DMTL fault is stored in the fault memory:
1. Clear the fault memory
2. Check whether the fuel filler cap is fitted correctly
3. Work through test module:
Complete vehicle
Drive
Engine control
Fuel tank system test
Fuel tank leak diagnosis module (DMTL)
This test module carries out a reference measurement and a fuel tank measurement and simultaneously
checks the function of the DMTL pump.
If the fault is stored again in the fault memory after this test module, the DMTL must be replaced, please refer
to Repair Instructions RA 16 13 015.
Important:
On no account open the DMTL!
Note:
Do not use lubricants during assembly.
After replacing the DMTL, clear the fault memory and once again work through the test module specified
above.
If the repair has been carried out correctly, the test module will not store a fault entry.
If, after replacing the DMTL, a leak is detected in the system, it is highly likely that a leak was caused during the
replacement procedure.
Note:
It is recommended to work through the above test module after all repairs to the fuel supply
system.
Case 2. Fault during tank leak detection (see Table 4)
Fuel tank faults indicate a leak in the fuel supply system or incorrect operation of the fuel filler cap.
Important:
The most common causes of a fuel tank leak fault are:
Fuel filler cap fitted crooked or not correctly
Fuel filler cap not turned as far as it will go to the end stop (the end stop is indicated by a
clearly audible ”click”)
Retaining strap for fuel filler cap trapped between the filler cap itself and the fuel filler neck
Note:
Also refer to Service Information SI 16 02 99 (501) with regard to the fault patterns listed above.
Proceed as follows if a tank leak fault is stored in the fault memory:
1. Clear the fault memory
2. Check whether the fuel filler cap is fitted correctly
3. Work through test module:
Complete vehicle
Drive
Engine control
System diagnosis
DMTL system test
For further details, please refer to Repair Instructions 16 00 102 (M54).
If a leak is detected in the fuel supply system on completion of the test module this leak will be caused by the
fuel filler cap not being closed correctly.
Important:
The costs in connection with the above causes are not incurred by any technical defects in the
system and no warranty claims for reimbursement will be accepted.
A fuel tank leak test must be carried out if the fuel supply system is found to be leaking.
Case 3. Tank leak search
The fuel tank leak test procedure is described in Repair Instructions 16 00 510.
With the ”DMTL pump actuation” service function, the internal solenoid valve (14, Fig. 2) in the DMTL closes the
line to atmosphere and the DMTL pump is subsequently activated.
As a result, the fuel supply system is a closed system and pressure is built up.
The leak can now be found with the aid of a leak detector.
Important:
1. External pressure must not be applied to systems with DMTL because, in this case, the
DMTL valve is not closed and a leak will inevitably be detected.
2. During the above service function, the DMTL pump runs uninterrupted for approx.
15 minutes. After this, the DME switches the DMTL pump off. If necessary, the test module
can be repeated after a short waiting period.
Probable leak points:
Fuel filler cap screwed on crooked or not up to the stop
(8, Fig. 2)
Fuel level sensor left or right leaking (replace sealing ring)
Connection between fuel filler pipe and fuel tank
Connections of filler vent line or of fuel tank vent lines I and II (16, 17, 18, Fig. 2)
Unlikely but possible leak points:
DMTL solenoid valve
Fuel evaporation control valve
Connection between DMTL and activated carbon filter (19, Fig. 2)
Pressure relief valve in the fuel filler cap
Mating between fuel cap and fuel filler neck
Note:
If a repair was previously carried out on the fuel supply system, the leak will probably be at the
repair location.
Important:
1. The pressure relief valve in the fuel filler cap can only be checked as described in Repair
Instructions RA 16 11 130.
2. If the mating between the fuel cap and the fuel filler neck is leaking, the fuel cap and the
fuel filler pipe (both!) must be replaced.
Case 4. Leak detector
The following devices can be used for leak detection purposes:
Devices that respond to ultrasound
Devices that respond to hydrocarbon hydrates
Part number of the device recommended by BMW (responds to hydrocarbon hydrates): 81 34 0 144 422.
Important:
Since, during normal vehicle operation, the vent line and the fuel evaporation control valve are
subjected to fuel vapours (fuel residue remains on the line and valve), leaks at the fuel
evaporation control valve cannot be detected effectively with devices that react to hydrocarbon
hydrates.
16 02 99 (501)
Introduction of new fuel filler caps for US models
E36 / Z3, , E38, E39, E46 US only
Complaint: An incorrectly sealed fuel filler cap leads to repeated incorrect warnings from the "CHECK
ENGINE" lamp in the instrument cluster. See section "Remedy": newly developed fuel filler
cap with improved sealing characteristics.
After refuelling and two or more engine cold starts, the "CHECK ENGINE" lamp lights up in the instrument
cluster. The following fault codes are stored in the DME fault memory after just one cold start following
refuelling:
M44 with DME M5.1:

OBD-2 code: P 0455

OBD-2 code: P 0442

OBD-2 code: P 0455

OBD-2 code: P 0442
M52TU with DME MS 42:

Description: Fuel system, major leak detected
OBD-2 code: P 0455

Description: Fuel system, minor leak detected
OBD-2 code: P 0442

Description: Fuel system, fine leak 0.5Â mm
OBD-2 code: P 0456
S52 with DME MS 41.2:

OBD-2 code: P 0455

OBD-2 code: P 0442

OBD-2 code: P 0442
S62 with DME MSS 52:

OBD-2 code: P 0442
M73 with DME M 5.2.1:

OBD-2 code: P 0442
Explanation: Within the framework of the OBD-2 systems checks legally required in the USA, the fuel tank
system is checked for leaks after each cold start (coolant temperature less than 30 degrees Celsius). To this
end, the tank system of vehicles with OBD-2 is checked for leaks while the engine is running. If the values
measured are not reliable, as it is the case with the filler pipe open, the fuel tank system is assumed to have
developed a leak. This leads to the fault codes stated above being stored after the first start test. After the
second start test, the "CHECK ENGINE" lamp will light up.
Note: Fault messages "major/minor leak" may also have other causes. Only the description "major leak"
indicates an inadequately sealed fuel filler cap.
Cause: Inadequately sealed fuel filler cap:
1. Result of insufficient sealing pressure at too small a closing angle. The fuel filler cap is
often not turned to the stop.
2. Retaining strap on fuel filler cap caught between the filler pipe and the fuel filler cap.
See Figure 1.
3. Refuelling with the engine running.
Figure 1: Retaining strap on fuel filler cap

1 Retaining strap
2 Filler pipe
3 Fuel filler cap

Affected vehicles:E36/Z3, E38, E39, E46, US versions only
E36/Z3 US from 07/1999

E38 US from 01/2000
E39 US from 06/1999
E39/2 US from 08/1998
E46 US from 07/1999
Remedy: Between 08/1998 and 01/2000, depending on model series, newly developed fuel filler
caps (see Fig. 2) with improved sealing characteristics were introduced. The force required
has been significantly reduced and the sealing effect and the acknowledgment "closing
procedure complete" have been improved. Despite this, the fuel filler cap must always be turned until it is
heard to have reached the stop.
Note: The fuel filler cap and the filler pipe form a single unit. The modified fuel filler cap cannot be retrofitted
individually.
Figure 2: Closing angle for the newly developed fuel filler caps
A Alignment range and free play = approx. 40 degrees
B Closing range = approx. 80 degrees
C Range of audible clicking noise = approx. 10 degrees
Note: The fuel filler cap will spring back, the clicking noise can be repeated at will.
Complete closing angle = approx. 130 degrees
Procedure:
1. Customer information:
Do not refuel the vehicle with the engine running, not even to keep the vehicle's air conditioner operating!
Important:
Refuelling with the engine running is prohibited in all countries due to the potential risk of fire in the area of
the filling station!
2. Follow the correct procedure to refit and seal the fuel filler cap properly. Make sure that the retaining strap
is properly positioned.
Please refer to enclosed customer information bulletin.
3. Following any maintenance work, repairs or checks on the vehicle (incl. the delivery inspection), the
following procedure should be followed:
a) Read out the DME control unit fault memory.
b) If the BMW fault codes ("Tank leak detected") are displayed, carry out the function check "Tank leak -
system check" via DIS.
c) Check that the fuel filler cap is correctly seated and correct if necessary. When doing this, make sure
that the retaining strap does not get caught.
d) Rectify any other faults which may be stored (besides the fault codes given).
e) Clear the fault code memory.
f) Attach the sticker to the fuel filler cap as necessary.
Sticker on upper section of fuel filler cap
Sticker on lower section of fuel filler cap
Parts: As required:
Sticker for upper section of fuel filler cap Part number 71 21 1 184 663
Sticker for lower section of fuel filler cap Part number 71 24 6 750 683
Packing unit: qty. 50
Reimbursement:Warranty reimbursement is not possible for customer information. This is primarily a
consultation or reminder of the correct procedure to be followed. Please refer to Owner's
Handbook.
The situation described in this Service Information bulletin, including the customer information bulletin,
should be made available to all sales staff with the request that customers are informed right from the
vehicle handover.
Defect code none
Job number none
Labour none
33 01 99 (403)
Snapping, knocking and smacking noises from the rear of the vehicle (rear axle/fuel
tank)
E46 saloon
Complaint: Snapping, knocking and smacking noises from the rear of the vehicle when pulling away,
cornering or driving over an uneven surface.
Cause: When driving over uneven surfaces or when cornering, the rear axle springs compress
and the uppermost coil of the barrel spring stick to the spring mounts.
When the spring then extends again, the coil is torn away from the spring mount causing
the noise described above.
These noises are transferred through the upper spring mount to the body and amplified.
Important!
These noises are frequently misdiagnosed as coming from the fuel tank.
This assumption is reinforced by the fact that the noises (temporarily) disappear when the fuel
tank is given additional support with tensioning straps.
This is a result of the vehicle being raised with a hoist. The relief of all load on the (rear) wheels
causes the position of the barrel springs relative to the spring mount to change, in turn causing
the noises to (temporarily) disappear.
On new vehicles, the fuel tank should in any case be completely filled to allow the tank to settle
properly due to the weight of the fuel.
The plastic fuel tank on the E46 is (as on the E39) elastically mounted by rubber-bonded
tensioning straps with a foam cushion between the tank and the body.
This mounting always allows the fuel tank a vertical movement of about
5-7 mm. Vertical forces (e.g. when a mechanic is checking the vehicle) then cause greater travel.
This play is required for the swelling of the fuel tank under the weight of the fuel (the swelling of
the fuel tank under the weight of fuel is completed after about 6-12 weeks under fuel) and when
the system is heated up (e.g. at high ambient temperatures).
It is thus not permissible to provide additional support for the fuel tank with tensioning straps.
This design can give the impression of the fuel tank being loose.
Affected E46/4
vehicles: start of series production until July 1998
Remedy: Coat the upper mounts of the rear axle barrel springs with talc.
Important!
Do not carry out any measures on the fuel tank !
Procedure: 1. In case of complaint, raise the vehicle with a hoist and remove the rear wheels.
2. If the spring mounts and barrel springs are very dirty, wipe them clean with a dry cloth (do
not remove barrel springs !)
Note:
- The spring mounts must not be cleaned with cleaning agents.
- Preservation wax on the spring mounts and coils does not have to be removed.
3.
Powder the spring mounts of the barrel springs (1) from the underside with commercially available talc. When
doing this, apply the talc evenly across the entire area of the spring mounts with a fine paintbrush.
4. When powdering the upper spring mount, it is unavoidable that talc will fall onto the lower spring mount.
Then this happens:
- Do not wipe the spring coils down.
- Spread the talc in the same way evenly across the entire area of the lower spring mounts with a fine
paintbrush.
Parts: Commercially available talc.
33 53 90 39 00
Talc spring mounts/rear axle
Labour 5 FRUs
Warranty type 1
Warranty stage 1
Reimbursement is limited to 36 months/100,000 km and only possible until June 2000 .

00 14 03 (047)
All model series
a single document.
hotspots:
E36 with M41 engine
E36, E53 from 01.01.1999
E36 up to E53 since 01.06.1999

E3 E34 E32 E31 R50 (MINI)
E30 E39 E38 E52 (Z8) R53 (MINI)
E36 E53 (X5) E65
E46 E60 E66
E67
E83 (X3)
Z1
Z3 (E36/7)
Z4 (E85)
1 / E81 - E87; 3 / E90-E93
5 / E60 - E61; 6 / E63 and E64; X3 / E83; X5 / E70, X6 / E71
Z4 / E85 and E86
MINI / R55, R56
33 01 06 (278)
Replacing tailpipe bracket on rear axle crossmember
E46 / M47TU
Complaint: Rattling noises can be heard when driving.
Cause: Material fatigue in exhaust suspension on the rear axle crossmember.
Affected E46 / M47TU (all body versions)

vehicles: Manufacturing period: from September 2003 to March 2006
Procedure: In case of customer complaint, fit new tailpipe bracket to the rear axle crossmember as
described in Enclosure 1.
Parts:
Description Part number Quantity
Repair set for tailpipe bracket, with following 33 31 6 778 690 1
contents:
- 1 x bracket
- 3 x blind rivet nut M8, stainless steel
- 5 x drilling template
- 5 x socket screw M8 x 25
- 2 x nut M8
33 00 90 13This defect code is not contained in the official Defect
Code Catalogue but has been included in the system, thus
enabling warranty claims to be processed.
Without additional repair work:
Fit tailpipe bracket to rear axle
Labour 7 FRUs
Within the scope of a visit tot he workshop:

Labour 5 FRUs
Warranty type 1

It is only permitted to make a claim for reimbursement under one of the above job numbers.
Reimbursement is limited to 36 months / 100,000 km and only possible until March 2009.
23 01 04 (063)
Gear lever sticks in 5th/reverse gear shift gate
E36/7, E36/M3, E38, E39, E46, E53 with GS5-280Z/320Z (C-transmission) and
GS5-39DZ (F-transmission)
Complaint: It is difficult to move the gear lever into and out of the 5th/reverse gear shift gate.
The gear lever does not automatically move from the 5th/reverse gear shift gate back to
the centre position
No shift gate guidance
Cause: Selector shaft locking pin sticking in bearing bush.
Affected vehicles:E46 M47, M47TU, M57

E46 M52TU/B28, M54/B30
E39 M47, M57
E39 Touring M52TU/B25, M54/B25
E39 M52TU/B28, M54/B30, M62/B35
E53 M54/B30, M57
E36/7 M52TU/B28, M54/B30
E36/7 S50 and S54
E36/M3 S50
E36/M3 US S52
E38 M51, M52TU/B28, M62/B35
Manufacturing period: September 1997 to December 2002
Remedy: Replace 5th and reverse gear locking pin bearing bushes.
Note:
In series production, improved bearing bushes were introduced in January 2003.
Procedure: In case of customer complaint, the 5th/reverse gear locking pin bearing bushes must be
replaced as described in Repair Instructions
23 11 565 (C-transmission) and 23 11 566 (F-transmission).
Note:
The transmission must be removed to replace the bearing bushes.
Special tools 23 4 021, 23 4 022 and 23 4 023 are needed to perform the repair.
Parts:
Part number: Part description: Quantity:
23 11 7 542 726 Repair kit for bearing bushes 1
Within the framework of a visit to the workshop -
Replace locking pin bearing bushes
Labour E36 Z3:

30 FRUs (E36 Z3/2.8/3.0 Roadster/Coupé)
35 FRUs (E36 Z3/M Roadster/Coupé up to Feb 2001)
36 FRUs (E36 Z3/M Roadster/Coupé from Feb 2001)
33 FRUs (E36 US Z3/M Roadster/Coupé)
E36/M3
38 FRUs (E36/M3 Coupé S50)
39 FRUs (E36/M3 Convertible S50)
47 FRUs (E36/M3 US S52)
E46:
37 FRUs (E46 Compact 318td)
34 FRUs (E46 Saloon 318d up to March 2003)
37 FRUs (E46 Saloon 318d from March 2003)
34 FRUs (E46 Saloon 320d up to Sep 2001)
39 FRUs (E46 Saloon 320d from Sep 2001)
40 FRUs (E46 Saloon 330d)
51 FRUs (E46 Saloon 330Xd)
37 FRUs (E46 Saloon 328i/330i)
37 FRUs (E46 US Saloon 328i/330i)
57 FRUs (E46 Saloon 325Xi/330Xi)
56 FRUs (E46 US Saloon 325Xi/330Xi)
34 FRUs (E46 Touring 318d up to March 2003)
37 FRUs (E46 Touring 318d from March 2003)
34 FRUs (E46 Touring 320d up to Sep 2001)
39 FRUs (E46 Touring 320d from Sep 2001)
51 FRUs (E46 Touring 330Xd)
37 FRUs (E46 Touring 328i/330i)
57 FRUs (E46 Touring 325Xi/330Xi)
56 FRUs (E46 US Touring 325Xi)
37 FRUs (E46 Coupé 328Ci/330Ci)
37 FRUs (E46 US Coupé 328Ci/330Ci)
38 FRUs (E46 Convertible 330Ci)
38 FRUs (E46 US Convertible 330Ci)
E39:
31 FRUs (E39 Saloon 528i up to Sep 1998)
30 FRUs (E39 Saloon 528i from Sep 1998)
30 FRUs (E39 Saloon 530i)
41 FRUs (E39 Saloon 525d/530d)
32 FRUs (E39 Touring 523i)
32 FRUs (E39 Touring 528i up to Sep 1998)
31 FRUs (E39 Touring 528i from Sep 1998)
31 FRUs (E39 Touring 520d)
41 FRUs (E39 Touring 525d/530d)
E38:
31 FRUs (E38 728i up to Sep 1998)
30 FRUs (E38 728i from Sep 1998)
36 FRUs (E38 735i)
27 FRUs (E38 725tds)
E53:
53 FRUs (E53 X5/3.0i)
52 FRUs (E53 X5/3.0d)
In case of order without additional repair operations -
Replace locking pin bearing bushes
Labour E36 Z3:

32 FRUs (E36 Z3/2.8/3.0 Roadster/Coupé)
37 FRUs (E36 Z3/M Roadster/Coupé)
35 FRUs (E36 US Z3/M Roadster/Coupé)
E36/M3
39 FRUs (E36/M3 Coupé S50)
40 FRUs (E36/M3 Convertible S50)
48 FRUs (E36/M3 US S52)
E46:
36 FRUs (E46 Saloon 318d up to March 2003)
39 FRUs (E46 Saloon 318d from March 2003)
52 FRUs (E46 Saloon 330Xd)
39 FRUs (E46 Saloon 328i/330i)
39 FRUs (E46 US Saloon 328i/330i)
59 FRUs (E46 Saloon 325Xi/330Xi)
58 FRUs (E46 US Saloon 325Xi/330Xi)
36 FRUs (E46 Touring 318d up to March 2003)
39 FRUs (E46 Touring 318d from March 2003)
52 FRUs (E46 Touring 330Xd)
59 FRUs (E46 Touring 325Xi/330Xi)
58 FRUs (E46 US Touring 325Xi)
39 FRUs (E46 Coupé 328Ci/330Ci)
39 FRUs (E46 US Coupé 328Ci/330Ci)
40 FRUs (E46 Convertible 330Ci)
40 FRUs (E46 US Convertible 330Ci)
E39:
32 FRUs (E39 Saloon 530i)
42 FRUs (E39 Saloon 525d/530d)
34 FRUs (E39 Touring 523i)
34 FRUs (E39 Touring 528i up to Sep 1998)
33 FRUs (E39 Touring 528i from Sep 1998)
33 FRUs (E39 Touring 520d)
43 FRUs (E39 Touring 525d/530d)
E38:
32 FRUs (E38 728i)
38 FRUs (E38 735i)
29 FRUs (E38 725tds)
E53:
54 FRUs (E53 X5/3.0i)
53 FRUs (E53 X5/3.0d)
Warranty type 1

Reimbursement is limited to 48 months / 100,000 km and only possible until December 2006.
00230301/0200
Gearbox oil drain plug leaking
E36, E39, E46
Situation: The thread flanks on the oil screw plugs for the manual gearboxes listed below have not
been made correctly.
Effect: As a result, drops of oil can form on the oil drain plug.
Affectedvehicles:E36, E39 and E46 S5D 200/250G (B-transmission) gearbox typeE39 (M5 and 540i) with
S6S 420G (D-transmission) gearbox typeProduction period: Corresponding to vehicle
identification number selection (January 1999 to January 2000)
Measure: In the event of a leaking oil drain plug, both screw plugs, the oil drain plug and oil filler plug
must be replaced, and the lifetime oil must be renewed.
Procedure: Check oil drain plug on gearbox for oil leaks. If leaking, replace both screw plugs, oil drain
plug and oil filler plug(tightening torque 40 Nm).The lifetime oil of the transmission is to be
replaced.
Attention:
For insurance reasons, the screw plugs are subject to obligatory return requirements from countries in the list
attached.
Please send the screws to this address:
Bayerische Motoren Werke AGDepartment VS-Q-1Heidemannstr. 164
80939 Munich
Parts: Designation: Part number: Quantity:
Plug 27 11 1 226 798 2x
Lifetime oil 83 22 9 408 942 5-litre canister
Note about the transmission oil fill amounts in Customer Service:Capacity S5D200/250G (B-transmission) 1.00
litreCapacity S6S 420G (D-transmission) 1.75 litres
00 23 03 01 00
Check oil drain plug for leaks. Replace screw plugs and renew lifetime oil if necessary.
Flat rate unit 3 FRUs5 FRUsE36/M3
Warranty type 1
Warranty level 1
Note:The lifetime oil (B-transmission 1.00 litre and D-transmission 1.75 litres) must be invoiced at the net value
(ex-factory price) listed under invoicing code 4.
23 03 98 (347)
Transmission difficult to shift/diagnostic aid
all model series
Complaint:
- Gears difficult to engage, especially 1st gear

- Gearshift mechanism catches
Note:
Field observations have shown the cause of transmissions being difficult to shift, especially of 1st
gear being difficult to engage, to be primarily the clutch and only in a few cases to be the
transmission itself. In order to trace the cause in the event of a complaint, the diagnostic aid
described below under the heading Procedure has been compiled.
Cause:
1. For possible causes if a clutch problem is diagnosed, please refer to procedure described
below:
- Taper spline of transmission input shaft not greased or grease dried out
Note on greasing taper spline:

Analyses have shown that grease used until now for greasing the taper spline ”Microlube GL261
BMW” is not suitable for prolonged exposure to high bell housing temperatures.
- Drive plate on transmission input shaft difficult to move

- Drive plate wobble
- Air in hydraulic system of clutch mechanism
- Release bearing defective or difficult to move in the guide sleeve
- Drive plate or clutch pressure plate broken
2. For possible causes if a transmission problem is diagnosed:
- External gearshifts difficult, e.g. shift rod joints stiff
- Gear lever rubber bellows incorrectly fitted, e.g. positioned too high or too low on the gear lever
- Soundproofing between the outer gear mechanism and the body incorrectly inserted, e.g. on the
wrong side or crumpled
Cause in transmission
- Synchronization faulty
- Inner gearshift mechanism stiff
- Water in transmission fluid (rare)
Affected All Models

vehicles:
Remedy: Actions to remedy difficult to move drive plate on transmission input shaft taper spline:
In 04/1998, the grease used to date to grease the taper spline ”Microlube GL261 BMW”
was superseded by the more temperature-resistant grease ”Esso UNIREX S2”.
In case of repair, the transmission input shaft taper spline is now only to be lubricated using the new ”Esso
UNIREX S2” grease.
The old grease ”Microlube GL261 BMW” is no longer to be used.
Procedure: In case of customer complaint, localize the cause by following the diagnostic aid described
below:
- The engine runs at idling speed

- Depress the clutch
- Try to engage 1st gear from neutral
If 1st gear is difficult to engage, hold the gear lever at the resistance point (about half total travel) with constant
force. Then switch the engine off with the other hand (ignition off).
Diagnosis 1:
If 1st gear is then engaged completely, i.e. the gear lever moves to the end position without any additional
pressure, there is a problem in the clutch.
Explanation:
Because the clutch does not uncouple completely, the transmission drive shaft transmits a residual torque
when the engine is running. This inhibits the release and meshing of the sliding sleeve at the end of the
synchronization process. Switching the engine off relieves the drive shaft of this torque.
A completely uncoupled clutch is thus simulated.
Remedial action for diagnosis 1:
Carefully clean the transmission input shaft taper spline and guide spigot to ensure that they are free from any
residue.
Then apply the taper spline grease ”Esso UNIREX 2” evenly and thinly with a paintbrush in the entire area of
the taper spline, including in the taper groove, and on the guide spigot.
Renew the drive plate.
For additional notes on troubleshooting and remedy:
Please refer to Service Information bulletin 21 01 97 (251).
Diagnosis 2:
If the gear lever remains at the resistance point, there is a problem in the outer gearshift mechanism or in
the transmission .
Remedial action for diagnosis 2:
troubleshooting as per cause 2.
Note on transmission installation:
Apply the taper spline grease ”Esso UNIREX 2” evenly and thinly with a paintbrush in the entire area of the
taper spline, including in the taper groove, and on the guide spigot. If the transmission is to be used again, the
taper spline must be thoroughly cleaned to ensure that it is free from any residue.
Parts: The new taper spline grease ”Esso UNIREX S2” is available through the customary parts
ordering channels.
Description Part number

”Esso UNIREX S2” (40g tube) 83 23 9 416 138
23 01 02 (881)
Transmission hard to shift
E36/7, E38, E39, E46 E53 with S5D 260Z/280Z/310Z/320Z
(C-transmission)
Complaint: Increased force needed to disengage gears and/or increased force needed up to gear
escapement when engaging gears.
Notes:
The complaint is only to be considered if it occurs with the transmission at normal operating
temperature. The viscosity of the oil means that incorrect diagnosis cannot be ruled out when the
transmission is cold.
When conducting diagnosis, please note also Service Information bulletin 23 03 98 (347)
(Transmission hard to shift).
Cause: Catch pin catches in pilot bore.
E46 M47 start of series production until August 2001

Affected vehicles:E46 M47 (318d) start of series production until March 2002
E46 M52TU B28, M54 B30 start of series production until March 2002
E39 M47 start of series production until March 2002
E39 M52TU B28, M54 B30, M62 B35 start of series production until March 2002
E39 M54 B25 (Touring) start of series production until March 2002
E53 M54 B30 start of series production until March 2002
E36/7 M52TU B28, M54 B30 start of series production until March 2002
E36/7 S50/S52 start of series production until July 2000

E36/7 S54 start of series production until March 2002
E38 M51, E38 M52TU B28, M54 B30, M62 B35 start of series production until end of series production
Remedy: Modified selector fork lock. The improved version has been installed in series production
since April 2002.
Procedure: In case of customer complaint, the catch pins for 1st/2nd, 3rd/4th and 5th/reverse gears
should be replaced as described in Repair Instructions RAE3923-23330. The transmission
must be removed to replace the catch pins.
Parts:
Part number: Description of parts: Quantity:
23 11 7 525 048 Set of catch pins 3
23 31 1 222 988 Sealing cap 3
Within the scope of a visit to the workshop - Install catch pins:
Labour 53 FRUs E53

36 FRUs E38
27 FRUs E38 725tds
30 FRUs E38 728i
30 FRUs E39
29 FRUs E39 525td/525tds
31 FRUs E39 523i/528i
32 FRUs E39 523 Touring/528i Touring
33 FRUs E39 535i
34 FRUs E39 535i from 9/98
30 FRUs Z3
33 FRUs Z3 US M-RO/US M-Coupé
35 FRUs Z3 M-RO/M-Coupé
37 FRUs E46
34 FRUs E46/318d/318d Touring/320d/320d Touring
38 FRUs E46/330 Convertible
56 FRUs E46US/four-wheel drive
57 FRUs E46/four-wheel drive
Install catch pins:
Labour 55 FRUs E53

38 FRUs E38
29 FRUs E38/725tds
32 FRUs E38/728i
32 FRUs E39
31 FRUs E39 525td/525tds
33 FRUs E39 523i/528i
34 FRUs E39 523i Touring/528i Touring
35 FRUs E39 535i
36 FRUs E39 535i from 9/98
32 FRUs Z3
35 FRUs Z3 US M-RO/US M-Coupé
37 FRUs Z3 M-RO/M-Coupé
39 FRUs E46
36 FRUs E46/318d/318d Touring/320d/320d Touring
40 FRUs E46/330 Convertible
58 FRUs E46/four-wheel drive
Warranty type 1

Reimbursement is limited to 36 months / 100,000 km and only possible until 31 March 2005.
23 02 02 (909)
Transmission hard to shift
E39, E46 with GS5-39DZ (F-transmission)
Complaint: Increased force needed to disengage gears and/or increased force needed up to gear
escapement when engaging gears.
Notes:
The complaint is only to be considered if it occurs with the transmission at normal operating
temperature. The viscosity of the oil means that incorrect diagnosis cannot be ruled out when the
transmission is cold.
Please note also Service Information bulletin 23 03 98 (347) (Transmission hard to shift) when
conducting diagnosis.
Cause: Catch pin catches in pilot bore.
Affected E46, E39 with M57 engine

vehicles: Manufacturing period: start of series production until March 2002
E46 with M47TU

Manufacturing period: September 2001 to March 2002
Remedy: Improved selector fork lock. The improved version has been installed in series production
since April 2002.
Procedure: In case of customer complaint, the catch pins for 1st/2nd, 3rd/4th and 5th/reverse gears
should be replaced as described in repair instructions
RAE3923-2330. The transmission must be removed to replace the catch pins.
Parts:
Part number: Description of parts Quantity:
23 11 7 525 048 Set of catch pins 3
23 31 1 222 988 Sealing cap 3
Within the scope of a visit to the workshop - Install catch pins:
Labour 40 FRUs E39/M57

41 FRUs E39/M57 touring
39 FRUs E46
40 FRUs E46 330d touring from 9/01
40 FRUs E46 330d from 9/01
50 FRUs E46 four-wheel drive
In case of order without additional repair operations - Install catch pins:
Labour 42 FRUs E39/M57

43 FRUs E39/M57 touring
41 FRUs E46
42 FRUs E46 330d touring from 9/01
42 FRUs E46 330d from 9/01
52 FRUs E46 four-wheel drive
Warranty type 1

Reimbursement is limited to 36 months/100,000 km and only possible until 31 March 2005.

24 02 98 (366)
Muffled knock during load reversal from the rear-axle area
E46 323iA and 328iA with A5S360R (GM5)
Complaint: Muffled knock (noise) immediately after a load reversal from the rear-axle area. Complaint
occurs primarily with vehicle at operating temperature.
Cause: Excessive side clearance between the gearbox output shaft and the gearbox output
flange.
Affected vehicles:323iA and 328iA with automatic gearbox A5S360R (GM5) up to gearbox number 7911.
Production period: Series launch up to August 1998
Remedy: New gearbox output flange with spring washer.
Notes:
The gearbox output flanges with white colour coding all round have already been
converted and are OK.
In gearbox production at the supplier, the output flange with spring washer was introduced from
gearbox number 7912 and no longer has any colour coding. The gearbox number is specified on
the gearbox type plate.
Procedure: In the event of a customer complaint, the noise must be localised during a test drive as
described below:
After reaching a speed of 30 to 40 km/h, put the vehicle at operating temperature into
coasting (overrun) mode, i.e. release the accelerator pedal suddenly. If a muffled knock from the rear-axle area
is perceptible immediately after the transition into overrun phase, the described cause is present.
Replace the gearbox output flange with the new version with a spring washer according to the repair
instructions.
See repair instructions 24 21 ...
Parts: Output flange repair kit, part number: 24 21 1 423 836
defect code catalogue but has been included in the system, thus
Replace output flange:
Warranty type 1
Warranty stage 1 (within vehicle warranty) 2 (outside vehicle warranty)
Invoicing is limited to 36 months/100,000 km and expires in September 2001.

24 02 03 (055)
Positive engagement in drive position D delayed
E46, E53, E83, E39 with A5S 390R (GM5 transmission)
Complaint: The first time drive position ”D” is engaged after a lengthy period out of use, e.g. over
night, the transmission only gains positive engagement with a time lag (longer than
2 seconds).
Cause: Leakage inside the transmission, C1 clutch empties during the parking period. As a result,
positive engagement is only gained with a time lag the first time a drive position is
engaged after a lengthy parking period.
Affected vehicles:Manufacturing period: September 2002 to end of series production

Series Engine Transmission
E39 M57 A5S 390R (GM5 transmission)
Manufacturing period: September 2002 to November 2003

E46 N42, M54, A5S 390R (GM5 transmission)
M47TU, M57 and M57TU
Manufacturing period: October 2002 to November 2003

E53 M54 and M57 A5S 390R (GM5 transmission)

E83 M54 and M57TU A5S 390R (GM5 transmission)
Remedy: E46, E53 and E39:

The pressure build-up for the C1 clutch has been optimised by means of a software
modification. Parallel to the series status, the improved data status can be found on DIS
CD 41.0 or later (or on the CIP DVD or later) and should be programmed using manual input in case of
complaint.
It is therefore no longer permissible to replace the transmission.
E83:
Replace automatic transmission.
Procedure: E46, E53 and E39:
In case of customer complaint, manually program the EGS control unit (EGS = electronic
transmission control) with DIS CD 41.0 (or with CIP DVD) or later.
(Please refer to Enclosure ”Manual programming procedure").
The data required for manual programming is:
Vehicle type Manufacturing period Part number of basic control

unit /
programmed EGS control
unit
Series E46:
316iA 09/02 until 11/03 7 518 709 / 7 552 728
318iA 09/02 until 11/03 7 518 709 / 7 552 730
318iA with option 204 09/02 until 11/03 7 518 709 / 7 552 732
(short HAG gear ratio)
318dA until 13.03.03 7 526 396 / 7 552 742
318dA 14.03.03 until 09/03 7 526 396 / 7 552 746
318dA from 09/03 7 544 721 / 7 552 754
320dA until 13.03.03 7 526 396 / 7 552 740
320dA 14.03.03 until 09/03 7 526 396 / 7 552 744
320dA from 09/03 7 544 721 / 7 552 752
325XiA ECE 09/02 until 08/03 7 518 709 / 7 546 846
325XiA ECE from 09/03 7 532 988 / 7 546 870
325iA US from 09/02 until 02/03 7 518 709 / 7 546 850
with MS43 engine
control system
325iA US 03/03 until 08/03 7 526 396 / 7 546 838
with MS45 engine
control system
325iA US from 09/03 7 532 988 / 7 546 862
325XiA US 09/02 until 08/03 7 518 709 / 7 546 848
325XiA US from 09/03 7 532 988 / 7 546 872
323iA Thailand 09/01 until 11/03 7 518 709 / 7 546 852
325iA Thailand from 12/03 7 518 709 / 7 546 874
330dA until 09/03 7 526 396 / 7 552 748
330dA from 09/03 7 532 988 / 7 552 756
330XdA until 09/03 7 526 396 / 7 552 750
330XdA from 09/03 7 532 988 / 7 552 758
330XiA ECE 09/02 until 08/03 7 518 709 / 7 546 840
330XiA ECE 09/02 until 08/03 7 518 709 / 7 546 844
with option 204 (short
HAG gear ratio)
330XiA ECE from 09/03 7 532 988 / 7 546 864
330XiA ECE from 09/03 7 532 988 / 7 546 868
HAG gear ratio)
330iA US Sport from 09/03 7 532 988 / 7 546 860
330iA US 09/02 until 08/03 7 526 396 / 7 546 836
330iA US from 09/03 7 532 988 / 7 546 858
330XiA US 09/02 until 08/03 7 518 709 / 7 546 842
330XiA US from 09/03 7 532 988 / 7 546 866
Series E39
525dA from 09/02 7 518 709 / 7 552 738
530dA from 09/02 7 518 709 / 7 552 736
Series E53:
X5 3.0dA 10/02 until 09/03 7 518 709 / 7 552 734
X5 3.0iA ECE 10/02 until 09/03 7 518 709 / 7 546 832
X5 3.0iA ECE from 10/03 7 532 988 / 7 546 854
X5 3.0iA US 10/02 until 09/03 7 518 709 / 7 546 834
X5 3.0iA US from 10/03 7 532 988 / 7 546 856
Series E83:
Replace automatic transmission as described in Repair Instructions 24 00 048.
Parts:
Model series / Model Description Part number Quantity
per
vehicle
E83 Exchange automatic 24 00 7 523 281 1
X3 3.0iA transmission
X3 3.0dA transmission
E83 Hexagon nut, self- 07 12 9 904 460 3
locking
(M12 x 1.5)
Program transmission control unit

E46, E53 and E39
Labour 5 FRUs
Replace exchange transmission

E83 / X3 3.0iA
Labour 56 FRUs

E83 / X3 3.0dA
Labour 60 FRUs
In case of order without additional repair operations:

E46, E53 and E39
Labour 6 FRUs

E83 / X3 3.0iA
Labour 57 FRUs

E83 / X3 3.0dA
Labour 62 FRUs
Warranty type 1

Reimbursement is limited to 36 months/100 000 km and only possible until November 2006.
24 02 98 (366)
flange.
Notes:
described below:
instructions.
Warranty type 1

24 02 98 (366)
flange.
Notes:
described below:
instructions.
Warranty type 1

24 02 03 (055)
Positive engagement in drive position D delayed
E46, E53, E83, E39 with A5S 390R (GM5 transmission)
Complaint: The first time drive position ”D” is engaged after a lengthy period out of use, e.g. over
night, the transmission only gains positive engagement with a time lag (longer than
2 seconds).
Cause: Leakage inside the transmission, C1 clutch empties during the parking period. As a result,
positive engagement is only gained with a time lag the first time a drive position is
engaged after a lengthy parking period.
Affected vehicles:Manufacturing period: September 2002 to end of series production

E39 M57 A5S 390R (GM5 transmission)
Manufacturing period: September 2002 to November 2003

E46 N42, M54, A5S 390R (GM5 transmission)
M47TU, M57 and M57TU
Manufacturing period: October 2002 to November 2003

E53 M54 and M57 A5S 390R (GM5 transmission)

E83 M54 and M57TU A5S 390R (GM5 transmission)
Remedy: E46, E53 and E39:

The pressure build-up for the C1 clutch has been optimised by means of a software
modification. Parallel to the series status, the improved data status can be found on DIS
CD 41.0 or later (or on the CIP DVD or later) and should be programmed using manual input in case of
complaint.
It is therefore no longer permissible to replace the transmission.
E83:
Replace automatic transmission.
Procedure: E46, E53 and E39:
In case of customer complaint, manually program the EGS control unit (EGS = electronic
transmission control) with DIS CD 41.0 (or with CIP DVD) or later.
(Please refer to Enclosure ”Manual programming procedure").
The data required for manual programming is:
Vehicle type Manufacturing period Part number of basic control

unit /
programmed EGS control
unit
Series E46:
316iA 09/02 until 11/03 7 518 709 / 7 552 728
318iA 09/02 until 11/03 7 518 709 / 7 552 730
318iA with option 204 09/02 until 11/03 7 518 709 / 7 552 732
(short HAG gear ratio)
318dA until 13.03.03 7 526 396 / 7 552 742
318dA 14.03.03 until 09/03 7 526 396 / 7 552 746
318dA from 09/03 7 544 721 / 7 552 754
320dA until 13.03.03 7 526 396 / 7 552 740
320dA 14.03.03 until 09/03 7 526 396 / 7 552 744
320dA from 09/03 7 544 721 / 7 552 752
325XiA ECE 09/02 until 08/03 7 518 709 / 7 546 846
325XiA ECE from 09/03 7 532 988 / 7 546 870
325iA US from 09/02 until 02/03 7 518 709 / 7 546 850
with MS43 engine
control system
325iA US 03/03 until 08/03 7 526 396 / 7 546 838
with MS45 engine
control system
325iA US from 09/03 7 532 988 / 7 546 862
325XiA US 09/02 until 08/03 7 518 709 / 7 546 848
325XiA US from 09/03 7 532 988 / 7 546 872
323iA Thailand 09/01 until 11/03 7 518 709 / 7 546 852
325iA Thailand from 12/03 7 518 709 / 7 546 874
330dA until 09/03 7 526 396 / 7 552 748
330dA from 09/03 7 532 988 / 7 552 756
330XdA until 09/03 7 526 396 / 7 552 750
330XdA from 09/03 7 532 988 / 7 552 758
330XiA ECE 09/02 until 08/03 7 518 709 / 7 546 840
330XiA ECE 09/02 until 08/03 7 518 709 / 7 546 844
HAG gear ratio)
330XiA ECE from 09/03 7 532 988 / 7 546 864
330XiA ECE from 09/03 7 532 988 / 7 546 868
HAG gear ratio)
330iA US Sport from 09/03 7 532 988 / 7 546 860
330iA US 09/02 until 08/03 7 526 396 / 7 546 836
330iA US from 09/03 7 532 988 / 7 546 858
330XiA US 09/02 until 08/03 7 518 709 / 7 546 842
330XiA US from 09/03 7 532 988 / 7 546 866
Series E39
525dA from 09/02 7 518 709 / 7 552 738
530dA from 09/02 7 518 709 / 7 552 736
Series E53:
X5 3.0dA 10/02 until 09/03 7 518 709 / 7 552 734
X5 3.0iA ECE 10/02 until 09/03 7 518 709 / 7 546 832
X5 3.0iA ECE from 10/03 7 532 988 / 7 546 854
X5 3.0iA US 10/02 until 09/03 7 518 709 / 7 546 834
X5 3.0iA US from 10/03 7 532 988 / 7 546 856
Series E83:
Replace automatic transmission as described in Repair Instructions 24 00 048.
Parts:
Model series / Model Description Part number Quantity
per
vehicle
X3 3.0iA transmission
X3 3.0dA transmission
E83 Hexagon nut, self- 07 12 9 904 460 3
locking
(M12 x 1.5)

E46, E53 and E39
Labour 5 FRUs

E83 / X3 3.0iA
Labour 56 FRUs

E83 / X3 3.0dA
Labour 60 FRUs

E46, E53 and E39
Labour 6 FRUs

E83 / X3 3.0iA
Labour 57 FRUs

E83 / X3 3.0dA
Labour 62 FRUs
Warranty type 1

Reimbursement is limited to 36 months/100 000 km and only possible until November 2006.
24 01 02 (822)
Working piston sealing cap leaking
E39, E46, E36, E34
Complaint: Automatic transmission leaking.
Cause: Oil loss at sealing cap (1) for 3-4 gearshift working piston in intermediate case
Affected E36, E34, E39, E46 with A4S 270/310R (THM-R1 transmission) from transmission serial
vehicles: number 4 071 106.
Manufacturing period: January 93 until August 99
Procedure: In case of customer complaint, replace the working piston sealing cap as described in
repair instructions 24 00 XXX.
Note:
Special tool 24 1 350 (tool set) is needed to perform this work correctly.
Parts: Part number 24 33 7 520 734 - Sealing cap repair kit
26 01 00 (652)
Cracking noise when pulling away
E46 / M47 Manual transmission
Complaint: Cracking noises from the propeller shaft when pulling away. The noise occurs primarily
when pulling away for the first time following a change of direction (forward/reverse).
Cause: Relative movement between the inner race of the centre bearing to the hub of the
propeller shaft fork, snapping noise.
Affected E46/E47 320d manual transmission
vehicles: Manufacturing period: from start of series production to April 2001.
Remedy: Retrofit dust cover to rear centre bearing.
Procedure: In case of customer complaint, remove the propeller shaft as described in Repair
Instructions 26 11 000.
Fig. 1
Important:
Clamp the propeller shaft in a vice only by the circumference edge (1) of the fork of the universal joint, see Fig.
1. In any other position it will be damaged. Use protective jaw inserts when clamping.
Fig. 2
Note:
The propeller shaft is balanced in the train. Mark the centre (2) and the rear section (1) of the propeller shaft in
a plane to reassemble in this position (see Fig. 2).
Fig. 3:
Unscrew bolt (1) and pull the propeller shaft apart (see Fig. 3).
When separating, do not strike the universal joint, but rather lever it apart with a pry bar or large screwdriver
between the bolt head and the universal joint.
Caution: Risk of pinching when unscrewing the bolt.
Clean the thread inside the propeller shaft and the thread of the bolt.
Note:
In production, the retaining bolt is fixed in the propeller shaft with Loctite. It can happen that the Loctite comes
into contact with and penetrates the taper spline. Such propeller shafts can only be separated with difficulty, if
at all. Propeller shafts which cannot be separated with a pry bar or large screwdriver must be replaced and
returned. However, these are absolutely isolated cases.
Fig. 4:
Press on the dust cover (1), see Fig. 4.

Press the propeller shaft together again in the marked position. Screw in the bolt with Loctite 270 and tighten.
Tightening torque 98 Nm.
Reinstall the propeller shaft.
Parts:
Dust cover 26 11 1 225 088 1
Propeller shaft for manual 26 11 1 229 569 1
transmission
Self-locking hexagon nut 07 12 9 900 047 3
catalogue but has been included in the system, thus enabling
warranty claims to be processed.
Fitting the dust cover to the rear centre bearing:

Labour 17 FRUs
Replacing the propeller shaft:
Labour 15 FRUs
As part of order without additional repair work:

Labour 19 FRUs

Labour 17 FRUs
Warranty type 1

Note:
Reimbursement is limited to 36 months / 100,000 km and only possible until June 2002.
Note:
If in isolated cases the propeller shaft has to be replaced, an adequate reason for the replacement must
be entered in the comments section of the warranty claim.
26 01 00 (652)
Cracking noise when pulling away
E46 / M47 Manual transmission
Complaint: Cracking noises from the propeller shaft when pulling away. The noise occurs primarily
when pulling away for the first time following a change of direction (forward/reverse).
Cause: Relative movement between the inner race of the centre bearing to the hub of the
propeller shaft fork, snapping noise.
Affected E46/E47 320d manual transmission
vehicles: Manufacturing period: from start of series production to April 2001.
Remedy: Retrofit dust cover to rear centre bearing.
Procedure: In case of customer complaint, remove the propeller shaft as described in Repair
Instructions 26 11 000.
Fig. 1
Important:
Clamp the propeller shaft in a vice only by the circumference edge (1) of the fork of the universal joint, see Fig.
1. In any other position it will be damaged. Use protective jaw inserts when clamping.
Fig. 2
Note:
The propeller shaft is balanced in the train. Mark the centre (2) and the rear section (1) of the propeller shaft in
a plane to reassemble in this position (see Fig. 2).
Fig. 3:
Unscrew bolt (1) and pull the propeller shaft apart (see Fig. 3).
When separating, do not strike the universal joint, but rather lever it apart with a pry bar or large screwdriver
between the bolt head and the universal joint.
Caution: Risk of pinching when unscrewing the bolt.
Clean the thread inside the propeller shaft and the thread of the bolt.
Note:
In production, the retaining bolt is fixed in the propeller shaft with Loctite. It can happen that the Loctite comes
into contact with and penetrates the taper spline. Such propeller shafts can only be separated with difficulty, if
at all. Propeller shafts which cannot be separated with a pry bar or large screwdriver must be replaced and
returned. However, these are absolutely isolated cases.
Fig. 4:
Press on the dust cover (1), see Fig. 4.

Press the propeller shaft together again in the marked position. Screw in the bolt with Loctite 270 and tighten.
Tightening torque 98 Nm.
Reinstall the propeller shaft.
Parts:
Dust cover 26 11 1 225 088 1
Propeller shaft for manual 26 11 1 229 569 1
transmission
Self-locking hexagon nut 07 12 9 900 047 3
catalogue but has been included in the system, thus enabling
warranty claims to be processed.

Labour 17 FRUs
Labour 15 FRUs
As part of order without additional repair work:

Labour 19 FRUs

Labour 17 FRUs
Warranty type 1

Note:
Note:
If in isolated cases the propeller shaft has to be replaced, an adequate reason for the replacement must
be entered in the comments section of the warranty claim.
31 01 99 (498)
Torsional oscillations in steering wheel when braking (update)
E46, except four-wheel drive and M3
Complaint: Torsional oscillations in steering wheel (steering wheel vibrations) when braking from 130
km/h to 60 km/h (80 - 40 mph).
Important!
The situation must not be confused with the steering wheel jerking on rapid brake application.
Please refer to Service Information bulletin 34 01 98 (373)
Cause: Front axle sensitivity.
Affected E46, start of series production until February 2001

vehicles: except E46 with option 0203 (”four-wheel drive system”) and except E46/M3
Remedy: In the event of a customer complaint:
Exchange steering articulated washer
(only LHD vehicles up to date of production 10/99)
Renew brake discs and brake pads on front axle
Balance the front wheels in a steady state and check for horizontal and vertical runout, match tyres as
necessary
Replace rubber mount on both control arms (incl. holder)
Procedure: 1. Exchanging steering articulated washer

This action only applies to LHD vehicles up to date of production 10/1999.
Note for diesel vehicles:
Check type/identifying feature of the installed steering articulated washer (identifying feature is only found
once on each articulated washer):
Type: Identifying feature:

A Original steering articulated washer Company symbol/Lemförder
B Modified steering articulated washer Figure ”50” in circle
Fig. 1:
A. Original steering articulated washer
(Identifying feature: company symbol/Lemförder)
B. Modified steering articulated washer
(Identifying feature: Figure ”50” in circle)
If the original steering articulated washer is installed in the vehicle, it must be exchanged for the modified
steering articulated washer.
Please refer to Repair Instructions 32 31 053
Note:
The modified steering articulated washer has been installed as standard on all E46 vehicles since
11/1999.
Important!
If a complaint is made and the vehicle already has pipes with variable orifice installed (part no. 32
13 6 750 847, see Fig. 2, detail B), these must be removed when the modified steering articulated
washer is installed.
It is not permitted to install both measures (pipes with variable orifice and modified steering
articulated washer)!
Fig. 2:
A. Pipes without variable orifice
B. Pipes with variable orifice
For information on removing the variable orifice, please contact the hotline of your subsidiary or importer.
2. Renewing brake discs and brake pads on front axle
This action applies to LHD and RHD models.
Renew both sets of brake discs and brake pads on the front axle.
Please refer to Repair Instructions 34 11 220.
3. Balancing the front wheels in a steady state and checking for horizontal and vertical runout, match
tyres as necessary.
Balance both front wheels in a steady state and check for horizontal and vertical runout, match tyres as
necessary (= turn on the wheel rim).
Important!
Proceed by following the following Repair Instructions and Service Information bulletins to the
letter as the success of the repair is otherwise jeopardised!
Repair Instructions 36 10 508
Service Information bulletin 36 01 95 (945), especially Point 5, ”Irregular running and its causes”
and Point 6, ”Tyre fitting”
4. Replacing holder with rubber mount on both control arms
Replace both holders with rubber mounts on the front axles.
Note:
When installing the holder with rubber mount, take care to ensure that only the approved version
corresponding to the control arm version installed is used.
Please refer to parts list.
Fig. 3:
A. Control arm version A
Installed in vehicles from start of series production until 07/1999
B. Control arm version B
Installed in vehicles since 07/1999 or following an exchange
Important!
On vehicles up to date of production 02/2001, two additional washers must be inserted on the
reinforcement cross.
Four additional washers must be inserted on the reinforcement plate.
Please refer to Repair Instructions 31 10 ... and
51 71 374.
Follow the procedures described in the above Repair Instructions to the letter!
Parts: For LHD vehicles only:
1x Articulated washer PN 32 30 6 752 957

2x Torx bolt M8 x 33 PN 32 30 1 094 718
All vehicles:
2x Brake disc, ventilated Please refer to EPC

1x Set of brake linings Please refer to EPC
1x Set holders with rubber mount ( ∅ 66 mm) for PN 31 12 6 757 622
control arm version A (see Fig. 3)
or

control arm version B (see Fig. 3)
4x Hexagon bolt with washer PN 31 10 1 095 140
M10x35
for holder with rubber mount
M10x35
for reinforcement cross
or
8x Hexagon bolt with flange PN 51 71 7 892 988

M10x30
for reinforcement plate
Retaining disc PN 31 10 6 757 145
2x for reinforcement cross
4x for reinforcement plate
Only for LHD vehicles which already have a ”pipe with variable orifice” (PN 32 13 6 750 847):
1x Set of pipes for LHD vehicles ZF PN 32 13 1 096 636

(discontinuation 04/99)
or

(introduction 04/99)
2x Flanged nut M10-10 ZNS PN 31 35 1 095 452

1x Torx bolt M8 x 33 PN 32 30 1 094 718
1 ltr. Hydraulic fluid As per BMW Service
Operating Fluids
Note:
Individual parts from the parts sets which have been valid until now may still be used to cover
standard requirements.
34 00 93 56 00
LHD vehicles:
Replace steering articulated washer, front brake discs with brake pads, both holders
for control arm; balance front wheels in a steady state
Labour Petrol engine: 30 FRUs

Diesel engine: 31 FRUs
LHD vehicles:
for control arm; match front wheels and balance in a steady state
Labour Petrol engine, 6-cylinder diesel engine: 35 FRUs

4-cylinder diesel engine: 36 FRUs
LHD vehicles:
for control arm; balance front wheels in a steady state; remove variable orifice

LHD vehicles:
for control arm; match front wheels and balance in a steady state; remove variable
orifice

LHD vehicles:
Replace front brake discs with brake pads and both holders for control arm; balance
front wheels in a steady state
Labour 28 FRUs
LHD vehicles:
Replace front brake discs with brake pads and both holders for control arm; match front
wheels and balance in a steady state
Labour 33 FRUs
RHD vehicles:
Labour 28 FRUs
RHD vehicles:
Labour 33 FRUs
Warranty type 1

It is only permitted to make a warranty claim under one of the above job numbers.
Note:
Steering hydraulic oil must be claimed under reimbursement code 4 (net amount).
Reimbursement is limited to 36 months/100,000 km and, as an exceptional rule due to the immediate

functional connection, also applies to brake discs and brake pads.
Reimbursement is possible until December 2002.

31 01 12 (833)
Warning!
Risk of fire!
31 01 04 (060)
Wheel control joint check
E46, E53
Situation: The task of the technical inspection organisations is, in addition to checking the vehicle for
compliance with regulations, to identify safety- and environment-relevant defects. The
BMW specialist departments have developed a special test procedure to check the
safety of the wheel control joint in accordance with the legal requirements within the framework of the periodic
vehicle inspection. This procedure enables the technical inspection organisations to check the wheel control
joint without having to use special tools. The method is described in full detail in the test catalogues of the
inspection organisations.
The established test procedure applies only on condition that the procedure agreed with the inspection
organisations is carried out exactly.
If this check produces a value which is outside the tolerance, the check with the BMW special tool would
already have produced this result at a much earlier stage.
Note:
E46:In the case of a single-joint/spring strut front axle this joint absorbs all the transverse and
longitudinal forces simultaneously. In view of the preload no noise caused by wear can be
discerned at this joint during customer operation.
If therefore disruptive noises are issued from the front end of the E46 during driving, it is highly
certain that the cause cannot be traced back to the joint!
E53:In the case of a two-joint spring strut front axle the transverse and longitudinal forces are
transferred by both joints. The joint wear on the wishbone and/or trailing link (wheel-side) is only
very rarely the cause of noises issuing from the front end.
Note: Check joints of anti-roll bar link on the anti-roll bar.
Effect: For warranty and goodwill claims it is essential to obtain an objective measuring result,
which can only be achieved using the BMW special tool 31 1 060, see SWS
01 09 03 (992). On completion of the check with the special tool, the test result must be
documented in the claim.
The associated service function must also be carried out:
Service functions > 02 Chassis and suspension > Front axle > Check wheel control joints
The diagnosis report showing the service function carried out in full must be attached to the warranty and
goodwill claim.
Note:
The often incorrectly applied method ”undefined shaking/vibrating” at the front wheel is not
permitted, because here the elasticities/tolerances intentionally scheduled by the design are
incorrectly evaluated on account of the complex axle geometry.
Enclosure 1 to SI 32 01 88 (828)
Concerns steering gear, steering column and steering shaft of:
Vehicle: ________________________________ Vehicle identification number:___________________

Accident repair of: _______________________ Customer: _________________________
Dealer: __________________________________ Dealer no.: _____________________
According to the manufacturer's instructions, the steering gear must be replaced after incurring accident
damage if one or more of the following points apply.
O Wheel rims in the event of a negative result from the wheel alignment check
O Spring struts, steering stubs and wheel carriers
O Wishbones
O Struts or trailing links or anti-roll bar with this function
O Body-side screwing/attachment points for wheel guide/control components
O Front axle support
O Pitman arms
O Track rods
O Steering box fixtures
O Steering Column
O Visible or noticeable damage to the steering box
O Unacceptable torque increase and jamming when the steering box is turned from limit position to limit
position (without hydraulic assistance)
O Permissible tolerances exceeded during wheel alignment check
The points marked with a cross have been identified as subsequent damage from the accident specified
above.
According to the manufacturer's instructions, the steering column/steering shaft must be replaced after
incurring accident damage if one or more of the following points apply:
O Visible or noticeable damage, deformation or breakage of the steering column or steering shaft
O Damage, permanent deformation or breakage of the track rod
O Unacceptable torque increase and jamming when the steering column is cranked from limit position to limit
O Permissible tolerances exceeded after wheel adjustment and wheel alignment (include alignment record
with invoice/report if necessary)
O Positive check for activated crash system of the steering column
above.
Important!
The vehicle's operating licence will be invalidated whenever the function of any of its safety components is
compromised!
The customer or the insurance company, contrary to the manufacturer's instructions, refuses to have the
steering gear replaced and thereby assumes responsibility for subsequent use of the steering gear/steering
shaft/steering column in the vehicle specified above and for the technical and legal consequences arising from
such use.
____________________________________________
Stamp/ Signature (Customer or Insurance Company)

Dealer: __________________________________ Dealer no.: _____________________
O Wishbones
O Pitman arms
O Track rods
O Steering Column
above.
above.
Important!
compromised!
such use.
____________________________________________

Dealer: __________________________________ Dealer no.: _____________________
O Wishbones
O Pitman arms
O Track rods
O Steering Column
above.
above.
Important!
compromised!
such use.
____________________________________________
31 01 99 (498)
km/h to 60 km/h (80 - 40 mph).
Important!

necessary


Fig. 1:
Note:
11/1999.
Important!
Fig. 2:
tyres as necessary.
Important!
Note:
Fig. 3:
Important!
51 71 374.

2x Torx bolt M8 x 33 PN 32 30 1 094 718
All vehicles:

or

M10x35
M10x35
or

M10x30

or


1x Torx bolt M8 x 33 PN 32 30 1 094 718
Operating Fluids
Note:
34 00 93 56 00
LHD vehicles:

LHD vehicles:

LHD vehicles:

LHD vehicles:
orifice

LHD vehicles:
Labour 28 FRUs
LHD vehicles:
Labour 33 FRUs
RHD vehicles:
Labour 28 FRUs
RHD vehicles:
Labour 33 FRUs
Warranty type 1

Note:


31 01 12 (833)
Warning!
Risk of fire!
00 30 11 (735)
All MINI
All Rolls-Royce
33 01 98 (327)
Life-time oil
E31, E36, E38, E39, E46
Situation: Since 09/97 (Model Year 98), only lifetime oils have been used in the rear axle differentials
of the above vehicles,
please refer to Service Information bulletin 00 19 97 (262).
There is no longer a necessity for an oil change on these rear axle differentials for the entire service life.
It is only necessary to correct the oil level within the scope of a repair,
e.g. when sealing.
Affected E31, E36 (except M3 and M roadster), E38, E39 and E46
vehicles: Manufacturing period since 09/97
Procedure: Only the following differential oils are to be used for topping up following
a repair (seal) of the rear axle differential:
Rear axle without differential lock OSP synthetic oil

Rear axle with differential lock MSP/A synthetic oil
Note:
The differential oils stated above are already available within the BMW dealer organisation and
are also to be used on earlier rear axle differentials.
Parts: For approved oils,
33 02 95 (007)
Changeover of differential oils
All models with optional equipment 209
Situation: A new oil for all differentials with a limited-slip differential (optional equipment 209) has
been approved for the launch of the Z3 Roadster. The new oil is called “BMW synthetic
final drive oil MSP/A” and will replace “BMW final drive oil MSP”.
Effect: The MSP oil must not be filled into the Z3 Roadster with limited-slip differential under any
circumstances. For such cases, MSP/A is mandatory, because an incorrect filling will lead
to creaking noises when driving.
Procedure: The rear axle final drives must be filled with the specified oils.
The MSP oil that is available in the dealer organisation can be used up in all models other
than the Z3 Roadster.
Parts: Hypoid oils for differentials with a disc self-locking differential
- BMW synthetic final drive oil MSP/A
55-l container 83 22 9 407 870

205-l container 83 22 9 407 871
- Castrol SAF-XJ
- Veedol SAF 44
33 01 98 (327)
Life-time oil
E31, E36, E38, E39, E46
Situation: Since 09/97 (Model Year 98), only lifetime oils have been used in the rear axle differentials
of the above vehicles,
There is no longer a necessity for an oil change on these rear axle differentials for the entire service life.
It is only necessary to correct the oil level within the scope of a repair,
e.g. when sealing.
Affected E31, E36 (except M3 and M roadster), E38, E39 and E46
vehicles: Manufacturing period since 09/97
Procedure: Only the following differential oils are to be used for topping up following
a repair (seal) of the rear axle differential:
Rear axle without differential lock OSP synthetic oil

Rear axle with differential lock MSP/A synthetic oil
Note:
The differential oils stated above are already available within the BMW dealer organisation and
are also to be used on earlier rear axle differentials.
Parts: For approved oils,
33 01 06 (278)
Replacing tailpipe bracket on rear axle crossmember
E46 / M47TU
Complaint: Rattling noises can be heard when driving.
Cause: Material fatigue in exhaust suspension on the rear axle crossmember.
Affected E46 / M47TU (all body versions)

vehicles: Manufacturing period: from September 2003 to March 2006
Procedure: In case of customer complaint, fit new tailpipe bracket to the rear axle crossmember as
described in Enclosure 1.
Parts:
Repair set for tailpipe bracket, with following 33 31 6 778 690 1
contents:
- 1 x bracket
- 3 x blind rivet nut M8, stainless steel
- 5 x drilling template
- 5 x socket screw M8 x 25
- 2 x nut M8
33 00 90 13This defect code is not contained in the official Defect
Code Catalogue but has been included in the system, thus
Without additional repair work:
Labour 7 FRUs
Within the scope of a visit tot he workshop:

Labour 5 FRUs
Warranty type 1

Reimbursement is limited to 36 months / 100,000 km and only possible until March 2009.
33 01 99 (403)
Snapping, knocking and smacking noises from the rear of the vehicle (rear axle/fuel
tank)
E46 saloon
Complaint: Snapping, knocking and smacking noises from the rear of the vehicle when pulling away,
cornering or driving over an uneven surface.
Cause: When driving over uneven surfaces or when cornering, the rear axle springs compress
and the uppermost coil of the barrel spring stick to the spring mounts.
When the spring then extends again, the coil is torn away from the spring mount causing
the noise described above.
These noises are transferred through the upper spring mount to the body and amplified.
Important!
These noises are frequently misdiagnosed as coming from the fuel tank.
This assumption is reinforced by the fact that the noises (temporarily) disappear when the fuel
tank is given additional support with tensioning straps.
This is a result of the vehicle being raised with a hoist. The relief of all load on the (rear) wheels
causes the position of the barrel springs relative to the spring mount to change, in turn causing
the noises to (temporarily) disappear.
On new vehicles, the fuel tank should in any case be completely filled to allow the tank to settle
properly due to the weight of the fuel.
The plastic fuel tank on the E46 is (as on the E39) elastically mounted by rubber-bonded
tensioning straps with a foam cushion between the tank and the body.
This mounting always allows the fuel tank a vertical movement of about
5-7 mm. Vertical forces (e.g. when a mechanic is checking the vehicle) then cause greater travel.
This play is required for the swelling of the fuel tank under the weight of the fuel (the swelling of
the fuel tank under the weight of fuel is completed after about 6-12 weeks under fuel) and when
the system is heated up (e.g. at high ambient temperatures).
It is thus not permissible to provide additional support for the fuel tank with tensioning straps.
This design can give the impression of the fuel tank being loose.
Affected E46/4
vehicles: start of series production until July 1998
Remedy: Coat the upper mounts of the rear axle barrel springs with talc.
Important!
Do not carry out any measures on the fuel tank !
Procedure: 1. In case of complaint, raise the vehicle with a hoist and remove the rear wheels.
2. If the spring mounts and barrel springs are very dirty, wipe them clean with a dry cloth (do
not remove barrel springs !)
Note:
- The spring mounts must not be cleaned with cleaning agents.
- Preservation wax on the spring mounts and coils does not have to be removed.
3.
Powder the spring mounts of the barrel springs (1) from the underside with commercially available talc. When
doing this, apply the talc evenly across the entire area of the spring mounts with a fine paintbrush.
4. When powdering the upper spring mount, it is unavoidable that talc will fall onto the lower spring mount.
Then this happens:
- Do not wipe the spring coils down.
- Spread the talc in the same way evenly across the entire area of the lower spring mounts with a fine
paintbrush.
Parts: Commercially available talc.
33 53 90 39 00
Talc spring mounts/rear axle
Labour 5 FRUs
Warranty type 1
Warranty stage 1
Reimbursement is limited to 36 months/100,000 km and only possible until June 2000 .

31 01 12 (833)
Warning!
Risk of fire!
00331801/0898
Weld seam on rear axle final drive absorber holder
E46 / M47 / 320d
Situation: During vehicle production it has been established that the absorber securing nut on the
absorber holder has not always been welded correctly.
Effect: The welded connection can break while driving and the vibration absorber then falls onto
the roadway. Damage to the vehicle underbody area around the rear axle and potential
danger to other road users cannot be ruled out.
Affected vehicles:E46/M47/320d Production period: Corresponding to list if vehicle identification numbers
(April to June 1998)
Measure: Replace holder for vibration absorber on rear axle final drive.
The absorber (if still there) can continue to be used.
Exception: If the absorber has already fallen off then this must be ordered together with the holder as a
complete assembly according to the Electronic Parts Catalogue. This procedure is only necessary in
extremely rare cases.
Procedure: Important:
Each step must be followed to the letter.
- Remove propeller shaft from rear axle final drive flange.
- Support rear axle final drive with transmission lifter and special toolÂ 33 4 390.
- Undo the differential cover screw connection to the rear axle support (rear rubber mount).
- Slowly lower the rear axle final drive until the top holder mounting bolt can be accessed. The lowest the
rear axle final drive may be lowered is until it is resting on the rear axle support.
- Unscrew holder and vibration absorber from the rear axle final drive.
Important: A vibration absorber must never be removed from, or secured to, the holder while the holder
remains fitted to the vehicle.
- Clamp holder and vibration absorber in vice and unscrew vibration absorber.
- Clamp new holder in vice and screw vibration absorber back on. Tightening torque: 78 Nm
- Refit holder together with vibration absorber to the rear axle final drive. Tightening torque of the 3 mounting
bolts (1): 45 Nm. The 4 cover mounting bolts that are still accessible (2) must also be checked for tight fit.
Tightening torque: Also 45 Nm.
- Lift the rear axle final drive and insert mounting bolt into rubber mount. Use new nut (PN 33 32 1 092 384) for
securing. Lift rear axle final drive using gearbox jack and tighten mounting bolt when in topmost position
(lowest propeller shaft deflection angle). Tighten via screw head and counter-hold on the nut. Tightening
torque: 174 Nm
- Refit propeller shaft to drive flange. Tightening torque: 85 Nm
Parts:
Absorber holder 33 11 1 428 772
Self-locking nut 33 32 1 092 384
00 33 18 01 00
Replace holder for absorber on rear axle final drive:
Labour 8 FRUs
Warranty type 1
Warranty level 1
34 02 09 (561)
Modified wear limit for brake disc / brake pad replacement
(BMW/MINI)
Situation: The wear limit of the minimum brake disc thickness (MIN TH) is modified analogue to the M-
vehicles from 'greater than or equal to' (â‰¥) to 'greater than' (>).
Affected vehicles:all BMW and MINI starting model year 2009
Procedure: The exact procedure for brake pad replacement is to be taken from the revised repair
instructions.
34 01 98 (373)
Steering wheel jerking on rapid brake application
Complaint: A ”jerk” can be felt in the steering wheel at all speeds when the brakes are applied rapidly.
This is felt in the form of a pulse, i.e. the ”jerk/vibration” is only felt at the very start of each
rapid brake application.
It is not possible to say which side the steering wheel will pull to first. The brakes work properly. Vehicle yaw is
not discernible.
Cause: Oversensitive front axle.
Affected
All E46 with DSC, except E46 with option 0203 (”four-wheel drive system”) and except
vehicles: E46/M3.
All E46 without DSC up to production date December 1999, except E46/M57 (”330d”).
Remedy: Vehicles with ”dynamic stability control” (DSC):

In case of complaint, the vehicle must undergo wheel alignment and the brake system
must be bled. Then test drive the vehicle to assess whether the fault has been rectified. If
necessary, replace the rubber mount of both front axle control arms.
Vehicles without ”dynamic stability control” (DSC):
In case of complaint, the vehicle must undergo wheel alignment and adjustment and a restrictor valve must be
retrofitted to the hydraulics of the front axle brake circuit. Then test drive the vehicle to assess whether the
fault has been rectified. If necessary, replace the rubber mount of both front axle control arms.
Procedure: Vehicles with ”dynamic stability control” (DSC):
1. Carry out a test drive and confirm the complaint. Then perform wheel alignment on the vehicle using the
kinematic diagnosis system (KDS).
If necessary:
- Adjust the front axle toe-in (with KDS).
- Adjust the front axle camber and toe-in (with KDS).

- Adjust the rear axle (with KDS).

Important!
When performing wheel alignment, it is important that the vehicle is set to the respective ideal/mean value
(without tolerance, values to left/right identical), even if the measured values are within tolerance.
2. Bleed the brake system.

Then carry out a test drive.
3. If the complaint is still present, examine the rubber mounts on both front axle control arms.
Important!
Only replace the holder with rubber mount if the rubber mount is leaking or if the rubber material is
damaged.
Note:
Both holders with rubber mount, left and right, must be replaced.
Note:
If the complaint cannot be rectified with actions 1 to 3, please contact the Hotline of your
Subsidiary or Importer.
Vehicles without ”dynamic stability control” (DSC):
1. Carry out a test drive and confirm the complaint. Then perform wheel alignment on the vehicle with KDS.
If necessary:
- Adjust the front axle toe-in (with KDS).
- Adjust the front axle camber and toe-in (with KDS).

- Adjust the rear axle (with KDS).

Important!
When performing wheel alignment, it is important that the vehicle is set to the respective ideal/mean value
(without tolerance, values to left/right identical), even if the measured values are within tolerance.
2. Install a restrictor valve in the front axle circuit of the tandem-brake master cylinder.
Note:
This restrictor valve is already installed on all vehicles without DSC manufactured since 12/99. If
necessary, check whether the restrictor valve is present before commencing work (see illustration
S34 98 007). If the restrictor valve is present, please continue operations with point 3.
Insert the pedal support and depress the brake pedal lightly. This will prevent brake fluid from escaping from
the tandem-brake master cylinder when the brake lines are separated. Siphon the hydraulic brake fluid from
its expansion tank and remove the expansion tank.
Release the brake line (A) of the front axle circuit at the tandem-brake master cylinder.
Screw the restrictor valve (B) into the hole in the front axle brake circuit on the tandem-brake master
cylinder and tighten.
Screw the brake line (A) of the front axle brake circuit into the restrictor valve (B) and tighten.
Important!
If necessary, bend the brake line slightly in the area of the bolt connection. The brake line must be
installed free of tension.
Tightening torque of the restrictor valve into the tandem-brake master cylinder and of the brake line into
the restrictor valve:
17 - 19 Nm each.
Install and refill the hydraulic brake fluid reservoir.
Then bleed the brake system.
Then carry out a test drive.
3. If the complaint is still present, examine the rubber mounts on both front axle control arms.
Important!
Only replace the holder with rubber mount if the rubber mount is leaking or if the rubber material is
damaged.
Note:
The holder with rubber mounts on the left and right must be replaced.
Important!
On no account is the restrictor valve to be installed on vehicles with ”Dynamic Stability
Control” (DSC). DSC control operations could be negatively affected.
Note on installation:
When installing the holder with rubber mount, take care to ensure that version corresponding to the control
arm version installed is used.
See Parts
A. Control arm version A installed in vehicles from start of series
production until 07/1999
B. Control arm version B installed in vehicles since 07/1999 or
following an exchange
Parts:
Restrictor valve (only for vehicles without 34 31 6 750 384 1
DSC)
Brake fluid 81 22 9 407 512 1000 ml
Set of holders with rubber mount 31 12 6 757 622 1
for control arm version A
Set of holders with rubber mount 31 12 6 757 623 1

for control arm version B
Hexagon bolt with washer, M10x35 31 10 1 095 140 4

Hexagon bolt with washer, M10x35 31 10 1 095 140 4

Hexagon bolt with flange, M10x30 51 71 7 892 988 8

Retaining ring 31 10 6 757 145

for reinforcement cross 2
for reinforcement plate 4
34 00 91 57 00
Electronic wheel alignment check (with KDS):
Labour 18 FRUs
Adjusting rear axle:
Labour 4 FRUs
Adjusting front axle:
Labour 5 FRUs
Adjust front and rear axles:

Labour 7 FRUs
Bleed brake system with DSC:
Labour 9 FRUs
Fit restrictor valve in front axle brake circuit and bleed brake system for ASC+T:
Labour 15 FRUs
Replace both holders with rubber mount for control arm:
Labour 14 FRUs
Warranty type 1
Warranty stage 1
Reimbursement is limited to 36 months/100,000 km and the deadline for submitting reimbursement claims is
December 2001.
00 13 03 (038)
Testing of four-wheel drive vehicles using brake test and performance test stands
E30, E34, E46, E53, E83
Situation: For operating BMW four-wheel drive vehicles on brake test stands, various guidelines
apply depending on the vehicle type.
Important.
Performance measurements on a single-axle roller-type test stand are generally not allowed, as a
total failure of the transfer case cannot be ruled out.
Affected vehicles:Vehicles with four-wheel drive:
E30 (four-wheel drive) from the start of series production

E34 (four-wheel drive) 05/1990 and 09/1991 to 12/1995
E46 (four-wheel drive) from the start of series production
E53 (X5) from start of series production until 09/2003 and from 10/2003
E83 (X3) from the start of series production
Procedure: When testing four-wheel drive vehicles on brake test stands, follow the various particular
instructions according to the specifications in Enclosures 1 to 5 for the relevant vehicles:
1. Enclosure 1 E30 (four-wheel drive)

4. Enclosure 4 E53 (X5)
5. Enclosure 5 E83 (X3)
31 01 99 (498)
km/h to 60 km/h (80 - 40 mph).
Important!

necessary


Fig. 1:
Note:
11/1999.
Important!
Fig. 2:
tyres as necessary.
Important!
Note:
Fig. 3:
Important!
51 71 374.

2x Torx bolt M8 x 33 PN 32 30 1 094 718
All vehicles:

or

M10x35
M10x35
or

M10x30

or


1x Torx bolt M8 x 33 PN 32 30 1 094 718
Operating Fluids
Note:
34 00 93 56 00
LHD vehicles:

LHD vehicles:

LHD vehicles:

LHD vehicles:
orifice

LHD vehicles:
Labour 28 FRUs
LHD vehicles:
Labour 33 FRUs
RHD vehicles:
Labour 28 FRUs
RHD vehicles:
Labour 33 FRUs
Warranty type 1

Note:


35 01 02 (892)
”Stick-slip” effect from accelerator pedal module
E38, E39, E46, E52, E53, E65, E66, R50, R53 / M47TU, M54, M57, M62TU,
N40, N42, N62, S54, S62, W10, W11
Complaint: Under unfavourable friction conditions, small pedal movements can only be applied to the
accelerator pedal in jerky motions (”stick-slip” effect).
This mainly occurs in high ambient temperatures or when warm air from the heating has
been flowing into the footwell for an extended period of time.
Important!
As the accelerator pedal's function and ability to move is not impaired, this is purely a comfort
issue for the customer and does not pose a safety risk.
Affectedvehicles:E38, E39, E46, E52, E53, E65, E66, R50, R53with M47TU, M54, M57, M62TU, N40, N42,
N62, S54, S62, W10, W11from production period until July 2002.
Remedy: In the event of a customer complaint, replace the accelerator pedal module and also the
adapter plate if necessary.
Procedure:
Remove accelerator pedal module, see
repair instructions RA 35 40 001.
Important!
If, after levering out, you cannot pull off of
the accelerator pedal module, then the
lock is catching on the second hook.
Lever off the second hook.
E38, E39, E46, E52, E53, R50, R53 only:
Read off part number of adapter plate while installed and

compare with the following table.
If the old version of the adapter plate is installed, replace with
the new version, see repair instructions RA 35 40 503.
E-series Part number of ”old” adapter plate version

E38, E39, E52, E53, R50 1 165 708
E46 left hand drive vehicle 6 751 143
(LHD)
E46 right hand drive 6 751 144
vehicle (RHD)
Quantity
Parts: Designation Part number
1x Accelerator pedal module for E38, E46, E39, 35 40 6 762 480
E53 with automatic transmission
1x Accelerator pedal module for E46, E39, E52, 35 40 6 762 481
E53 without automatic transmission
1x Accelerator pedal module for E65, E66 35 41 6 762 482
1x Accelerator pedal module for R50, R53 with 35 40 6 762 483
automatic transmission
1x Accelerator pedal module for R50, R53 without 35 40 6 762 484
automatic transmission
1x Adapter plate for R50(new version) 35 40 0 141 446
1x Adapter plate for E38, E39, E52, E53(new 35 40 6 756 719
version)
1x Adapter plate for E46 LHD(new version) 35 40 6 756 720
1x Adapter plate for E46 RHD(new version) 35 40 6 756 721
Replace accelerator pedal module
Flat rate unit 3 FRU (E52, E65, E66, R50, R53)2 FRU (E39, E46, E53)
Replace accelerator pedal module (during a workshop visit)
Flat rate unit 1 FRU
Replace accelerator pedal module and adapter plate
Flat rate unit 3 FRUs
Replace accelerator pedal module and adapter plate (during a workshop visit)
Flat rate unit 1 FRU (E38, E39, E46, E53)2 FRU (E52, R50, R53)
Warranty type 1
Warranty stage 1 (under vehicle warranty)2 (outside vehicle warranty)
Invoicing is restricted to 36 months/100,000 km and expires in July 2005.

36 02 98 (377)
General information on tyre pressure control (RDC)
E38, E39, E46, E53
Situation: Tyre pressure control continuously monitors the tyre pressure of the vehicle's wheels,
even when it is being driven. The RDC will report a significant drop in tyre pressure in one
or more tyres.
Vehicles with tyre pressure control can be recognised as such by:
- the RDC button on the right of the steering column under the instrument cluster (E38/E39) or in the centre
console (E46/E53).
- the metal tyre valves.
This system has been on the market as an option since 10/1998. To preempt the possibility of incorrect
operation by the customer or by the dealership, the following procedure should be followed.
Procedure: The system must be activated before the vehicle is delivered to the customer (please
refer to the Owner's Handbook):
1. Set the tyre pressures as specified on the tyre inflation plate / in the Owner's Handbook.
2. Switch the ignition on (engine off).
3. Press and hold the RDC button until the reset action is verified in the instrument cluster (about 6
seconds). The words ”Tyre pressure set” appear in the upper instrument cluster and the yellow indicator
lamp with the tyre symbol lights up in the basic instrument cluster.
4. When handing over a new vehicle, the customer should be advised to carefully read the sections of the
Owner's Handbook headed ”Tyre Pressure Control”, ”Check Control”, ”Instrument cluster”, ”Indicator and
warning lights” and ”Tyre pressures”.
Technical notes:
The spare wheel is fitted with a wheel electronic module but is not monitored by the system. If the antennae
on the two rear wheel housings receive signals from the spare wheel electronic module (depending on the
position of the spare wheel electronic module), a warning will only be given if the pressure in the spare wheel
drops below 1.3 bar. For this reason, the customer should be advised to check the tyre pressure of the spare
wheel at regular intervals.
Emergency wheels are not fitted with wheel electronic modules.
All wheels approved by BMW can have a wheel electronic module retrofitted.
All running wheels on the car must have a wheel electronic module fitted or else the words ”Tyre press. contr.
inactive” will appear after a few minutes in the upper instrument cluster and the yellow display symbol will light
up in the basic instrument cluster.
If the car has suffered a flat tyre and the defective wheel is placed in the luggage compartment or in the spare
wheel well, the tyre pressure warning message will remain active for a few minutes after the journey is
resumed. This condition will continue until the RDC has cleared the defective wheel as a running wheel from
the position allocation memory. In isolated cases, the defective wheel in the luggage compartment / spare
wheel well may again (depending on the position of the wheel electronic module) trigger a warning whenever
the RDC button is pressed (see notes above).
If wheels fitted with a wheel electronic module are being carried inside the vehicle (e.g. winter tyres), these
could trigger an ”inactive” warning as the control unit is only able to monitor repeated radio signals from no
more than 5 tyres. To preempt this warning, special tyre sacks which isolate these radio signals can be used
for the transportation of individual tyres. These tyre sacks can be ordered as part number 36 13 9 416 536
from the BMW parts sales department (only for E38/E39/E46) (so long as stocks last). To ensure that the
radio signals are properly isolated, it is sufficient to simply fold the open end of the sack to.
For technical reasons, the transmission output of the wheel electronic modules on the E53 has had to be
increased. For this reason, the tyre sacks described above can no longer be used as the signals are not
screened with 100% efficiency. In such cases, the customer should be advised that the warning ”Tyre
press. contr. inactive” could appear and the yellow warning lamp could light up. This indicates that the
system must be reactivated after the wheels have been unloaded.
Tyre pressures are also monitored by the tyre pressure control system when the vehicle is stationary with the
ignition off (key withdrawn). When work is being carried out in the workshop, the warning ”Tyre defect” may be
triggered when the ignition is switched on, if for example the wheels have been removed and the air let out of
the tyres in order to change the tyres, provided that the vehicle can still receive the radio signals from the
wheel electronic modules (range: approx. 20 m). This warning will not be cancelled until the same wheel
electronic module again reports the pressure which was present in the respective tyre before the air was
released. Alternatively, the new tyres should be fitted and inflated to the specified tyre pressure and the RDC
button pressed.
Used wheel electronic modules in the vicinity of the workshop can trigger flat tyre warnings on the car from
which they were removed, provided that their radio signals can still be received by this vehicle (range: approx.
20 m). This can be prevented by wrapping the wheel electronic modules in aluminium foil (1-2 layers is
sufficient) after they have been removed.
New wheel electronic modules are mute (i.e. they do not transmit radio signals) provided that they have never
either been installed on a wheel or had pressure applied. It is therefore not necessary to screen new wheel
electronic modules.
More detailed instructions and background material can be found in the BMW Service Training paper ”Tyre
pressure warning systems”.
36 02 98 (377)
E38, E39, E46, E53
or more tyres.
console (E46/E53).
Technical notes:
button pressed.
electronic modules.
36 02 98 (377)
E38, E39, E46, E53
or more tyres.
console (E46/E53).
Technical notes:
button pressed.
electronic modules.
36 0106 (251)
Inflating tyres with nitrogen (N2)
All series
Situation: The question is regularly asked, whether inflating the tyres with nitrogen instead of air has
any benefit with respect to a ”gradual loss of tyre pressure”. This process is also known as
diffusion (diffusion is the movement of miniscule particles, especially atoms or molecules).
Statement
Some companies regard inflating the tyres with nitrogen as a way of selling the customer a feature that has no
practical benefit whatsoever with respect to diffusion. As nitrogen has larger molecules, it would indeed be
logical to argue in favour of inflating the tyres with nitrogen instead of with air. However, the improvement
achieved is only marginal because air is anyway made up of about 78 % nitrogen.
Composition of air:
78 % nitrogen (N2)
21 % oxygen (O2)
<1 % inert gases
0.03 % carbon dioxide (CO2)
The reduced rate in the drop in pressure inside the tyre is just a few hundredths of a bar over several months.
Inflating the tyres with nitrogen does not relieve the driver from his duty (described in the Owner's Handbook)
to check the tyre pressures regularly. Nitrogen is used in aviation and in motor racing because, in the event of
an accident and the associated risk of fire, no additional oxygen should be fed from the tyres.
Affected All series
vehicles:
Procedure: Recommendation
BMW does not recommend inflating tyres with nitrogen. Should individual customers wish
to have their tyre inflated with nitrogen, their wishes may be accommodated.
36 03 99 (484)
Information on tyre pressure control (RDC)
E38, E46, E39
Situation: If the message ”Check tyre pressure” appears in the instrument cluster, or the yellow LED
(basic instrument cluster) lights up, you should correct the air loss in the tyres at the next
opportunity (loss of air due to natural diffusion under normal operating conditions). If the
tyre pressure is corrected without performing the ”Set tyre pressure”, implausible RDC messages may occur
and the LED may light up.
Action: After correcting the air pressure, with the engine off and terminal 15 on, press the ”Tyre
pressure set button” and hold (approx. 6 seconds) until the words ”Set tyre pressure”
appears in the instrument cluster (high cluster) or the yellow LED lights up. If implausible
tyre pressure messages occur thereafter, check whether the ”Set tyre pressure” was performed properly after
the tyre pressure was corrected.
The RDC is set to trigger the message ”Check tyre pressure” after a loss of just 0.2 bar (text or yellow lamp).
When checking pressure, this pressure differential cannot be detected to this degree, particularly in the
transition period from the cold season to the
warm season.
Moreover, it should be noted that this pressure differential can be caused by differences in the inflators used.
At vehicle handover or in case of defective tyres, please note the Service Information bulletin 36 02 98 (377).
SI 36 02 98 (377)
Procedure: Further situations which may cause implausible RDC messages:
- Unfavorable wiring harness routing in the vicinity of the control unit:

There must be no tight radii or even kinks or bends in the cable routing of the wiring harness to the control
unit.
- Incorrectly routed wiring at the control unit:

Make sure that all wires leading to the control unit are routed correctly. Wires which are tangled or twisted
around each other must be avoided.
- Incorrectly engaged connectors in the vicinity of the xenon headlights:

All connectors in the vicinity of the xenon headlights must sit securely and be properly engaged. Loose or
incorrectly engaged connectors could cause malfunctions in the RDC when the xenon headlights are
switched on.
- Current-carrying cables in the vicinity of the reception aerials:

The RDC reception aerials, which are located in the wheel housings, must not be positioned anywhere
other than the location at which they are fitted in the factory. No current-carrying wires are to be routed
under or adjacent to the aerials.
- Radar warner:
Operating a radar warner can also cause malfunctions in the RDC.
- Cordless headphones or similar:

If a complaint occurs repeatedly, deactivate any retrofit equipment which uses a transmission frequency or
which may have an effect on the electromagnetic compatibility of the vehicle.
36 02 06 (279)
Repairing runflat tyres
All models
Situation: The question is regularly asked whether a repair should be performed on runflat tyres after
a loss of pressure.
Runflat tyres
(also known as ”tyres with emergency running characteristics”)
can be recognised by a circular symbol on the side wall bearing
the letters RSC (Runflat System Component).
Note:
As a general rule, BMW has never recommended repairs on tyres. However, should individual
customers wish to have their tyre repaired, their wishes may be accommodated.
A list of tyre manufacturers who approve or disapprove of repairs to runflat tyres can be found in the section
headed ”Procedure”.
Procedure: 1. Contact the local representative of the tyre manufacturer concerned.
2. Please note the following when naming the nearest authorised tyre dealer for runflat tyres:
Tyre manufacturers who approve of repairs on runflat tyres (under certain conditions):
Michelin
Dunlop
Goodyear
Bridgestone
Tyre manufacturers who disapprove of repairs on runflat tyres:
Pirelli
Continental
31 01 99 (498)
km/h to 60 km/h (80 - 40 mph).
Important!

necessary


Fig. 1:
Note:
11/1999.
Important!
Fig. 2:
tyres as necessary.
Important!
Note:
Fig. 3:
Important!
51 71 374.

2x Torx bolt M8 x 33 PN 32 30 1 094 718
All vehicles:

or

M10x35
M10x35
or

M10x30

or


1x Torx bolt M8 x 33 PN 32 30 1 094 718
Operating Fluids
Note:
34 00 93 56 00
LHD vehicles:

LHD vehicles:

LHD vehicles:

LHD vehicles:
orifice

LHD vehicles:
Labour 28 FRUs
LHD vehicles:
Labour 33 FRUs
RHD vehicles:
Labour 28 FRUs
RHD vehicles:
Labour 33 FRUs
Warranty type 1

Note:


41 03 09 (537)
Min/max tolerance sample catalogue for paintwork and corrosion damage
All
Situation: Min/max tolerance samples are available to enable improved pinpointing of paint and
corrosion damage. They are a supplement to the BMW Paintwork publication announced
in Service Information 41 01 08 (452) and published in October 2008.
Vehicles that are older than three years after the first registration date may only be repaired by replacing
components if the damage exceeds a defined extent (see min/max tolerance samples). With immediate effect,
certain paint damage patterns attributed to incipient corrosion may only be repaired by means of spot repairs
as small as possible.
There are currently five max/min tolerance samples:
Paintwork damage with min/max tolerance sample A (critical damage pattern)
Paintwork damage with min/max tolerance sample B (minor damage pattern)
Paintwork damage with min/max tolerance sample C (scrape marks)
Paint damage with tolerance sample D (rubber grommets)
Paint damage with min/max tolerance sample E (vehicle underbody)
All customer complaints are to be classified based on these additional min/max tolerance samples.
1. Min/max tolerance sample A (critical paintwork damage)
General appearance: Rust is visible without scratching the surface.
Sample A1:
Visible rusting on fold and its seal (1).
Sample A2:
Bubbling on outside (1) of fold seal.
Note:
Bubbling between fold seal and outer edge. The fold seal
covers an approx. 5 mm wide strip at the edge of the
component.
Sample A3:
Bubbling on the inside of the fold seal (1) is more extensive than the width.
2. Min/max tolerance sample B (minor paintwork damage)
General appearance: Rust is NOT visible without scratching the surface.
Sample B1:
Bubbling on the inside of the fold seal (1) is less extensive
than the width. Lengthwise distribution is less than the width of
the fold seal (1).
Sample B2:
Bubbling on the inside of the fold seal (1) is less extensive
than the width. Lengthwise distribution is greater than the width
of the fold seal (1).
3. Min/max tolerance sample C (scrape marks)
Sample C1:
Scrape marks on paint surface of the tailgate (2) by plastic
trim (1) (only Touring).
Sample C2:
Chafe marks on paint surface caused by tailgate handle strip (1) on tailgate (2).
3. Tolerance sample D (rubber grommets)
Formation of blisters is not visible without lifting the rubber

grommet (1).
3. Min/max tolerance sample E (vehicle underbody)
Visible red rust formation originating from an edge or a spot-

weld.
Procedure: The damage patterns are now differentiated based on min/max tolerance samples. The
following extended warranty applies:
Not for damage Period in years Selection of the repair

caused by method
customer First registration after
1.1.2004
Min/max tolerance 12 Component

sample A replacement if feasible
in terms of time
Min/max tolerance 3 Component
sample B replacement
Min/max tolerance from 3 NO part exchange
sample B permitted. The
approval regulations of
the local market must
be observed at all
times.
Min/max tolerance 12 Paint
sample C
Tolerance sample 12 Paint
D
Min/max tolerance 12 Seal and preserve.
sample E
The paint structure must be built up as specified in the ColorSystem painting handbook.
Attention!
The repair is only carried out in justified case of customer complaint.
In the case of rust damage and paint damage, all mounted parts must be retained wherever
possible and remounted as part of the repair procedure.
In contentious cases, e.g. repeated repairs, the advise of the respective Warranty department
should be sought in order to clarify the procedure.
41 01 04 (079)
Cracks in rear axle mount (inspection on customer request)
E46
Situation: In rare cases, cracks can occur in the rear axle mount. Mostly the rear left rear axle mount
is affected and in rare cases additionally the front right rear axle mount.
Cracks can occur due to extreme stress as the result of load reversal especially in driving
school applications, trailer towing, extreme sport-orientated driving style as well as the installation of non-
approved sport suspensions.
Affected vehicles:E46
Procedure: The rear axle mount should be inspected as follows only on the express request of the
customer:
1. Drive vehicle on to vehicle hoist.
2. Important: Take particular care when lowering the rear axle to ensure that the cable for the tilt sensor is
not damaged.
Undo the two rear bolts on the rear axle. Slightly lower the rear axle (approx. 10 cm).
3. Check the area of the rear left rear axle mount for cracks.
4. If cracks are found, proceed corresponding to Service Information 41 03 03 (025) .
Checking the rear axle support as part of a workshop visit:
Labour 5 FRUs
Checking the rear axle support as part of order without additional repair work:
Labour 6 FRUs
Warranty type 1
Warranty level 1 (within vehicle warranty) 2 (outside vehicle warranty)
Only one of the job numbers specified above may be used for billing. Repairs are to be charged under the
defect code specified in Service Information 41 03 03 (025).
41 01 98 (374)
Dent repairs without damaging paintwork
All
Situation: Light dents have previously only been repaired through conventional means such as
Multispot and filling followed by repainting.
However, methods of rectifying parking and hailstone damage that do not damage the
paintwork are becoming increasingly common.Vehicle insurers are fully supportive and endorse this approach.
This procedure involves pressing out damage from the inside of sheet metal panels using levers followed by
polishing. The total outlay is much lower than for conventional dent repairs with subsequent repair painting. It is
to be noted here that some areas of damage cannot be reached on account of reinforced or bonded body
components. For safety reasons, no additional holes may be drilled to improve accessibility.
The size of the dent should not exceed a diameter of 80 mm.
This procedure can also be used during general workshop repair processes, such as:
- Preparing for painting (reduction in filling work)
- Rectifying any damage following repair painting.
Based on this background as well as environmental aspects and the positive effect on insurance coverage
classification, this method of repairing dents without paintwork damage is approved for BMW vehicles. This
approval only applies to dents that do not have visible paintwork cracks.
Procedure: Repairing dents without damaging the paintwork requires continuous practice and a high
degree of skill. In order to cater for the relevant situation at all contractual partners, two
application methods for optimum use are offered.
1. In the same way as professional body and paintwork shops are already used, it is also possible in this
case to commission qualified contractors for the purpose of conducting dent repairs without paintwork
damage.
2. Purchase of a BMW pressing-out tool set for dent repairs.
The form and materials of this set have been carefully selected for BMW vehicles. It consists of a
standard set (for approx. 80 % of the outer body skin that can be reached) and an extension set (for the
remaining 20 %).
Training is recommended so that the tool set can be used effectively. This training is offered by external
companies and can be conducted locally (e.g. for Germany the company Ur-Form).
See Service Information 5 04 98 (328).
Note:
Make sure that the training provider does not conduct training under the prerequisite of
purchasing his particular set of pressing-out tools.
41 03 03 (025)
Fractures on rear-axle support
E46
Situation: In isolated cases, fractures may occur on the rear-axle support. In most cases, the rear
left support is affected. In isolated cases the front right support may also be affected.
These fractures could result in noises from the area of the rear compartment/rear axle.
Fractures may be caused by extreme loads due to strong load shifts, especially in operation in diving schools,
trailer towing, an extreme sporty driving style or if non-approved sport suspension systems are installed.
Manufacturing period: start of series production until February 2000
Procedure: In case of customer complaint or during inspection, check the rear-axle support for
fractures and if necessary fill the area of the rear-axle support with foam. It may be
necessary to fit a repair part first.
Following a major repair, the customer must be given a declaration that the vehicle has not depreciated in
value as a result of the repair and that the repair was not performed as the result of an accident. ( Please
refer to Enclosure 1)
Proceed as follows when examining and performing the repair:
1. Position vehicle on lifting platform.
2. Check the area of the rear left rear-axle support for fractures. Fractures may emanate from welding
points
(please refer to figure 1).
If no fractures can be found, continue troubleshooting or the inspection.
Figure 1
3. In case of severe damage with fractures greater than 20 mm, continue with point 6.
If minor fractures are found, the rear axle must be lowered slightly. Continue with step 4.
4. Important!
When lowering the rear axle, take care to ensure that the cable for the tilt alarm sensor is not
damaged.
Loosen the two rear-axle bolts.
Lower the rear axle by approx. 10 cm.
Check the rear-axle support for fractures again.
5. If fractures smaller than 20 mm are found, continue with point 7. If larger fractures are found, continue with
point 6.
6. If fractures larger than 20 mm are present:
Install the repair part. Please refer to Repair Instructions ”Replacing rear-axle support”, RA 41 11 400.
Adjust the rear axle
Perform wheel alignment
Important
Photographic documentation must be compiled prior to performing the repair measures
described in point 6. These photos are to be filed in the vehicle records as evidence.
7. If fractures smaller than 20 mm are found, or after the repair part has been fitted, fill the rear-axle member
with foam in the area of the rear left rear-axle support.
Note:
The procedure described below is applicable to a single version. Account must be taken for vehicle-
specific differences according to prevailing circumstances.
To do this, proceed as follows:
a) Remove the floor trim in the luggage compartment.
b) Prepare holes for injecting cavity foam and structuring foam as follows
(see Fig.2).
Figure 2
- Hole (1) is already present and is sealed with a plug

- Drill hole (2) in the middle between hole (1) and the corresponding hole on the right-hand side of the
vehicle:
Used a 10 mm stepped drill bit.
- Hole (3) is already present and is covered by the anti-vibration liner. Expose the hole using suitable
tools.
Important.
Use disposable gloves to prevent contact with the skin!
Note:
Before injecting the cavity foam, fill the hose with a trial injection.
c) Inject cavity foam into holes (2) and (3) as follows.

- Hole (2):
Insert hose approx. 120 mm (under hole (2) there is a reinforcement plate with hole already present
- the hose must also be fed through this hole).
Inject cavity foam for approx. 1 second (press through once). Pull the hose approx. 3 cm back while
injecting.
- Hole (3):
Inject cavity foam for approx. 0.5 second.
Note:
To make it easier to work with the structuring foam, preheat the structuring foam to approx. 60°C,
e.g. in a water bath.
d) After approx. 10 minutes waiting period, injec the structuring foam from both cartridges into hole (1)
using special tool 41 3 010.
Below this hole, there is another hole through which the hose must also be fed.
Verification of order: Special tool 41 3 010 was dispatched directly to the workshops by the company
Cartool and can also be ordered from Cartool using the number stated.
e) Remove any protruding structuring foam from the holes and seal these with plugs.
f) Reassemble the vehicle and allow the foam to harden for 24 hours.
Important
The vehicle must not be driven during the hardening period
(may only be pushed).
Parts: Description: Part number: Quantity:
Fit rear-axle member
repair part:
Rear-axle member 41 11 7 000 246 1
repair part
Noise insulating 51 48 8 204 055 1
material, rear floor
Noise insulating 51 48 8 204 049 1
material, luggage
compartment floor
Anti-vibration liner 51 48 8 165 271 1
Anti-vibration liner for 51 48 8 160 470 1
luggage compartment
recess
Small parts as required
Fill rear-axle support
with foam:
Cavity foam 83 42 9 410 694 1
Structuring foam 83 42 0 307 530 1
Plug, 10 mm 51 71 1 906 001 1
Plug, 12 mm 07 14 7 127 539 1
subject to current warranty terms.
If the paintwork is performed by a BMW dealer, net material costs for paintwork, cavity
coating and underbody protection can be reimbursed using reimbursement code 04.
If the paintwork is outsourced, i.e. contracted to an outside paintshop, net costs can be reimbursed as outside
payment for paintwork using reimbursement code 03.
Direct and indirect costs (loan vehicle, costs for subsequent official inspection, etc.) may be reimbursed
through warranty at net price using the appropriate reimbursement code. Documentation should be filed in the
vehicle records.
Defect code 41 11 91 01 00This defect code is not contained in the official Defect Code Catalogue
but has been included in the system, thus enabling warranty claims to be processed.
Within the framework of a visit to the workshop - Fill rear-axle member with foam in area
of rear-axle support.
Labour 9 FRUs
In case of order without additional repair work - Fill rear-axle member with foam in area
of rear-axle support:
Labour 11 FRUs
Within the framework of a visit to the workshop - Fit rear-axle member repair part and fill
rear-axle member with foam in area of rear-axle support (paintwork outsourced):
Labour
361 FRUs for Type Code No. AL11
(for other models, please refer to KSD-CD)
In case of order without additional repair work - Fit rear-axle member repair part and fill
rear-axle member with foam in area of rear axle support (paintwork outsourced):
Labour 363 FRUs for Type Code No. AL11

Within the framework of a visit to the workshop - Fit rear-axle member repair part, paint
and fill and rear-axle member with foam in area of rear-axle support:

In case of order without additional repair work - Fit rear-axle member repair part, paint
and fill rear-axle member with foam in area of rear axle support:

Warranty type 1

A claim for reimbursement can be made under one of the above job numbers only.
41 01 08 (452)
New BMW paint brochure
All
Presentation of BMW paint brochure:
The existing BMW paint brochure has been thoroughly revised and in its new form provides good reference for
assessing all kinds of paint and corrosion damage.
The examples and detailed descriptions contained in the brochure are intended to find a standard language for
identifying paint and corrosion damage. Unambiguous descriptions of damage mean that misinterpretations
can be largely ruled out when assessing a possible warranty claim. Communication between the customer and
the authorised BMW dealer during assessment on the vehicle is also made greatly easier.
If for example the following damage is unambiguously identified on the paint surface, this will always be
considered to be the responsibility of the customer, and warranty will be ruled out:
Mechanical influences on the paint surface (e.g. scratches)
Damage to the paint surface caused by chemical or biological influences (e.g. animal droppings)
The new BMW paint brochure complements the BMW paint handbook when eliminating paint and corrosion
damage. This means that the repair procedures described in the BMW paint handbook are adapted
unambiguously and purposefully to the fault pattern.
Subsequent orders for BMW paint brochure:
The BMW paint brochure can be ordered via the usual parts-related channel under the BMW parts number 01
29 2 148 332.
41 02 09 (521)
New repair methods ”Gluing / Riveting” on steel bodies
BMW/MINI
Situation: Advance technical developments in the field of adhesives and equipment technology
have made modified repair methods possible. This procedure has been tested and
approved following exhaustive endurance runs and corrosion tests in the Development
division.
Similar to the procedure for the tail panel on the F01/F02, the repair methods "welding/soldering" will change to
"gluing/riveting" on various outer skin and structural components of steel bodies from the launch of the E89
and R57. This procedure has already been introduced for repair work on the reduced-weight aluminium front
end (GRAV) of the E60.
The repairs can be performed by all workshops that have participated in a GRAV or the current bonding and
riveting training, in combination with the training video.
Another positive point of this method is the significantly improved corrosion protection resulting from the wide-
area bonding of the spare part coating (KTL).
Procedure: Essentially, the following components are affected:
Rear side wall
Tail panel
Boot floor
Roof outer skin
engine carrier
support carrier
Model series affected:
MINI (R55, R56, R57)
BMW 1 Series (as of E8x)
3 Series (as of E9x)
5 Series (as of E60)
X1 (E84)
X5 (E70)
X6 (E71)
Z4 (E89)
7 Series (as of F01)
And all future series.
Necessary workshop equipment:
Punch riveting tool
Cartridge gun for body glue
Universal collet (for roof ducts)
Infrared lamp
For more information on the required tools, see Service Information.
Parts required:
The new parts and consumables required for the respective scope of repair work are listed in the Electronic
Parts Catalogue (EPC).
In addition, vehicle-specific service repair packages are also offered. Here, the vehicle identification number is
to be entered in KSD2, the corresponding "Packages" button selected and the required job item selected in
main group 41.
Repair instructions:
The repair instructions have been revised to take account of the new repair method:
To differentiate the individual repair methods, the repair stage is inserted in the repair instructions.
Repair stage 1: All repairs that only provide for replacement of screwed/bolted components and
planishing operations.
Repair stage 2: Repairs that are carried out by bonding and riveting without the use of a straightening
bench.
Repair stage 3: Repairs that are carried out by bonding and riveting with the use of a straightening bench
or welding.
Training video for bonding and riveting:
The new methods, for example "punch riveting", have been described on a training video that will be distributed
to National Sales Companies.
Please make sure the training video is made available to the staff who will be performing this work and, if you
do not perform body repair in your own workshop, to the staff of your specialist body workshop.
The BMW paint brochure can be ordered via the usual parts-related channel under the BMW parts number
01 69 0 037 577.
Time allowances:
Time allowances (flat rates) have been revised to take account of the new repair methods and shall apply
retrospectively.
41 02 07 (377)
Repair of corrosion damage
All
Situation: A paint brochure is available for the evaluation and repair of body components relating to
corrosion damage.
It contains examples for the definition of paint and corrosion damage and provides
information on remedies and repairs. Details on contents and distribution were published in the Service
Information (bulletin) 41 01 08 (452).
The procedure for chafe marks (e. g. tailgate repair) is described in detail in the vehicle-specific Service
Information (bulletin).
Chafe mark on a painted surface generally are not considered to justify a part replacement.
Procedure: Important!
Repair of corrosion damage only if there is a specific customer complaint!
To the extent that the design allows, all add-on parts must be retained and converted.
Always adhere to the following procedure when dealing with corrosion damage:
1. Establish the fault pattern of the damaged area with the aid of the new paint brochure and use this as a
basis to determine the repair measures.
2. Remove the partial area of the body as specified in the repair instructions.
3. Repair the partial area affected by corrosion in accordance with the repair instructions and the BMW paint
manual.
4. Reassemble the vehicle using the removed add-on parts.
Note:
Only the following repairs of the body components may be invoiced.
Replacement of the corroded body component (only in case of rust damage without partial
repair)
Paint
Conversion of add-on parts
Cavity preservation
41 02 99 (435)
Replacement of rear axle trailing arm fixture
E46
Situation: After correcting the toe-in on the rear axle, the securing bolts for the rear axle trailing arm
fixture can no longer be tightened to the specified torque.
If too much torque is applied (tightened with screwdriver), it is possible for the thread to
shear.
As the walls of the bushings are relatively thin, it is not possible to carry out a repair using HELICOIL threaded
inserts.
Effect: A tight fit of the securing bolts for the rear axle trailing arm can no longer be guaranteed.
Affected E46/4
vehicles: Manufacturing period: Start of series production until calendar week 28/1998.
Action: In case of complaint, the trailing arm fixtures, left and right, are to be replaced.
Procedure: Remove the complete rear axle.

Remove the fuel tank.
Use a welding point drill to drill out damaged trailing arm fixtures, left and right, at the 10 welding points, marked
with a spot (please refer to Fig. 1).
Two or three welding points should be ground out at poorly accessible areas.
Fig. 1
Important! Do not drill through.
Before removing the fixture, the position should be clearly scored with a scribe. After removing the damaged
part, clean the surrounding are for the forthcoming welding work. When doing this, take care not to remove the
scored contours.
For safety reasons, an additional two plug welds (1) and 4 seam welds should be applied in addition to the 10
plug welds already provided (please refer
to Fig. 2).
Fig. 2
The pre-marked welding points and the additional welding points should be drilled out to 8 mm for plug welding.
Each plug weld should be completed without interruption, to prevent flaws and air pockets (corrosion).
It is must be ensured that the cavity sealing is not burnt during welding.
Finally, apply sufficient cavity sealing through the hole in the wheel housing and through the three threaded
bushings.
Immediately after the repair, carefully treat, prime, paint seal and protect all areas which in their original state
were sealed with body sealing compound in accordance with BMW guidelines.
Reassemble the vehicle, adjust the front and rear axles.
Please refer to Repair Instructions 32 00 610/620
Parts: Description Part number
Trailing arm fixture, left 41 11 7 012 047
Trailing arm fixture, right 41 11 7 012 048
41 11 90 04 00
Replace rear axle trailing arm fixtures,

left and right
Labour 140 FRUs - 318i saloon

134 FRUs - 320d saloon
138 FRUs - 320i/323i/328i saloon
135 FRUs - 323i/328i saloon USA
Warranty type 1 (within vehicle warranty)
Warranty stage 2 (outside vehicle warranty)

00410701/0598
Seal rear left spring strut support bearing
E46 /4
Situation: It is possible that the rear left support bearing was not correctly installed.
1. The opening in the spring strut dome for the support bearing has not been sealed.
2. The support disc on the spring strut dome was not installed.
3. The support disc on the spring strut dome was erroneously fitted between the support bearing and the
spring strut dome.
Effect: This can lead to water ingress into the luggage compartment in unfavorable conditions.
Moreover, the correct installation of the support disc increases the stability of the spring
strut screw connection.
Affected E46/4 - Manufacturing period: as per list of vehicle identification numbers (start of series
vehicles: production until February 1998).
Action:
1. Seal support bearing with Terostat.

2. Install support disc.
3. Reinstall an incorrectly installed support disc in the correct position.
Procedure:
1. Remove rear left trunk wheel housing trim.

(please refer to repair instructions 51 47 151)
2. Fill the gap between the support bearing and the spring strut dome with Terostat tape (length 150 mm)
(item 1 in figure).
3. Moreover, install the support disc (item 2 in figure) if it is not installed. Renew the collar nuts (item 3 in
figure) and tighten to the specified torque.
4. If the length of thread on the support bearing (M8) is insufficient for installing the support disc, this is an
indication that the disc is installed on the wrong side (see Situation, point 3).
1. Relieve the load on the rear axle with a workshop hoist.
2. Unscrew the support bearing screw connection at the spring strut dome.
3. Take the support bearing from the underside of the wheel housing and reinstall it in the correct
position (see item 2 in figure). Renew the collar nuts and tighten to the specified torque.
Reassemble the vehicle, install the trunk wheel housing trim.
Parts: Terostat 81 (150 mm) - PN 81 22 9 407 488
This part number is not to be submitted for reimbursement.
Support disc 51 71 8 255 291

Collar nut 31 33 1 092 887
Special defect code subject to current warranty terms as follows:
00 41 07 01 00
Seal support bearing with Terostat and install support disc if necessary.
Labour 5 FRUs
Seal support bearing with Terostat and reinstall support disc in correct position.
Labour 5 FRUs
Warranty type 1
Warranty stage 1
31 01 12 (833)
Warning!
Risk of fire!
51 02 02 (834)
Cleaning and care of leather in vehicles
All model series
Situation: The leather used by BMW is a high-quality natural product prepared using state-of-the-art
processing techniques.
As it is a genuine natural product, its specific characteristics and peculiarities must be
taken into account in its use and care.
Lengthy periods in direct sunlight (for convertibles) may lead to slight bleaching and loss of softness in the
leather.
Regular cleaning and care are necessary, for dust and dirt from the road (leather's arch enemy) can penetrate
the pores and folds, causing the leather to lose its visual appeal.
Affected vehicles:All BMW vehicles with leather finish
Action: As dirt and grease slowly attack the protective coating of the leather finish on a vehicle,
treatment with BMW's premium leather care agent is needed once or twice a year,
depending on the degree of soiling.
Here, the precleaned leather surfaces of the seats, door trims and dashboard can be cleaned and cared for in
a single work cycle.
Procedure: 1. Preclean the leather surface with a microfibre cloth.
2. Thinly apply BMW's premium leather care agent with a soft, clean sponge (by-pack)
(shake well before use). Rub into soiled areas more intensively.
3. Allow to dry and the rub down with a clean cloth (by-pack).
Note:
BMW premium leather care agent:
High-quality oils maintain the natural characteristics of the leather. The typical smell of leather is
refreshed.
This product provides UV protection (combined leather cleaning and care agent). It was
presented in September 1999 and has been available from BMW Parts Service since January
2002 in two different containers.
Important!
Work using BMW premium leather care agent cannot be reimbursed through warranty as this is a
cleaning and care operation.
Parts:
Part number Description Quantity
83 12 0 411 413 Leather care kit with UV protection 1
Note:
Current contents and range of parts can be found in the spare parts catalogue.
51 01 00 (530)
Front licence plate holder
All models
Situation: Most BMW dealers use a licence plate backing panel with their company name for fitting
the rear licence plate.
The same backing panel is also frequently used for the front licence plate.
Effect: Fitting such a backing panel to the front bumper is a contravention of licencing regulations
74/483 EEC as it does not meet the specification for protecting pedestrians.
Extract from EC Directive 74/483: "No protruding section of the exterior surface of the
vehicle shall have a rounding-off radius of less than 2.5 mm".
The consequence is the invalidation of the German Federal Vehicle Homologation Approval and serious
disadvantages for the BMW dealer in the event of litigation.
Moreover, the name of the dealership on the licence plate backing panel adjusts the height of the licence
plate, so impeding the cooling air inlet and negatively affecting the cooling efficiency of the engine at high
loads.
Affected All models.
vehicles:
Procedure: Do not install a separate licence plate backing panel on the front bumper. The licence plate
backing panel fitted at the factory corresponds to all requirements regarding safety,
operation and styling.
Important! To prevent rattling noises being caused by the licence plate, the foam-rubber strips in the by-pack
kit must be used as backing and attached double-sided to the licence plate and to the vehicle.
All necessary securing screws and white or coloured cover flaps can be found in the by-pack kit.
Parts: Standard licence plate backing panels and mounting components are listed according to
model in the Electronic Parts Catalogue and can be ordered via the customary parts
ordering channels.
51 02 02 (834)
All model series
leather.
Note:
refreshed.
Important!
Parts:
Note:
51 02 02 (834)
All model series
leather.
Note:
refreshed.
Important!
Parts:
Note:
51 02 02 (834)
All model series
leather.
Note:
refreshed.
Important!
Parts:
Note:
51 02 02 (834)
All model series
leather.
Note:
refreshed.
Important!
Parts:
Note:
51 02 02 (834)
All model series
leather.
Note:
refreshed.
Important!
Parts:
Note:
51 02 02 (834)
All model series
leather.
Note:
refreshed.
Important!
Parts:
Note:
51 02 02 (834)
All model series
leather.
Note:
refreshed.
Important!
Parts:
Note:
51 06 01 (780)
Gear indicator failed
E46/RHD
Complaint: Gear indicator in the selector lever cover does not change when the automatic selector
lever changes.
The gear indicator in the instrument panel continues to function as normal.
Cause: Display band with mark is torn.
Affected vehicles:E46/RHD Saloon with 4-speed automatic transmission Production period: Series
introduction until September 1999.
Remedy: If a customer complaint is received, replace the selector lever cover.
As of CW 26/2001, only revised covers for the selector lever have been provided from
the Dingolfing parts warehouse.
Procedure: Replace cover for selector lever (see REP 51 16 210)
Parts: Selector lever cover, part number: 51 16 8 208 798
51 16 95 01 00This defect code is not in the official defect code
catalogue, but it has been entered in the system. This enables
warranty invoicing.
Replace selector lever cover:
Labour 2 FRUs
In the case of order without additional repair work: Replace selector lever cover:
Labour 1 FRU
Warranty type 1
Warranty level 1
Invoicing is restricted to 36 months/100,000 km and time-limited until October2002.

51 04 97 (278)
Information sticker exterior paintwork
All Models
Situation: The information sticker for the exterior paintwork will be affixed manually at the familiar
points in the engine compartment up to the end of 1997. As from January 1998, these
information stickers will be discontinued for vehicles equipped with EC type identification
plates. The information concerning the exterior paintwork will be provided in the bottom section of the new EC
type identification plate with laser inscription.
Effect: The separate identification sticker will still be used for all other
country-specific versions and individual types of paint but now with laser inscription.
Affected All Models
vehicles:
Procedure: All BMW models from the Munich, Dingolfing, Regensburg and South Africa production
plants will be equipped with the new EC type identification plate as from January 1998.
Spartanburg will follow at a later date.

65 11 00 (617)
Radio CD 43: CD is not ejected
E46
Complaint: CD is not ejected from the radio.
Cause: Production residue on the wooden finisher in the area of the radio.
Affected E46 with fine wood finish (option 438) and Radio Business CD (option 662)
vehicles: Manufacturing period: September 1998 to March 2001 (production period extended from
October 1999 to March 2001).
Remedy: Remove injection burr from the wooden finisher in the area of the radio.
Procedure: In event of customer complaint, the wooden finisher in the area of the radio must be
reconditioned:
if the radio finisher strip is drawn over the CD slot (see illustration).
Take off the wooden finisher and remove the residue from the central area (middle) of the aluminium carrier
section with a triangular scraper. Bevel the edges. Install the wooden finisher with pressure towards the
driver's side.
Note: As a basic rule, only standard CDs without additional adhesive labels may be used.
Do not rework the wooden finisher in the area of the radio:
if the radio finisher strip runs parallel with the wooden finisher (see illustration).
If the problem is not rectified, an internal fault in the radio can be assumed.
65 10 91 29 00Remove production residue from the wooden
finisher.
Labour 3 FRUs
Warranty type 1

51 05 98 (372)
Stowage compartment
E46
Complaint: Cover for the stowage compartment in the centre console does not open or close.
Cause: Cracked material in the area of the spring.
Affected E46
vehicles: Manufacturing period: 02.06.1998 to 20.07.1998
Remedy: An improved stowage compartment is installed in series production.
Procedure: In the event of a complaint, the stowage compartment must be renewed.
Parts:
Description Part number
Stowage compartment 51 16 8 202 188
Labour 2 FRUs
Warranty type 1
Reimbursement is only possible until 2001 and is limited to 36 months/100,000Â km.

51 02 02 (834)
All model series
leather.
Note:
refreshed.
Important!
Parts:
Note:
51 01 09 (551)
Measures for leather complaints (seats)
All model series
Situation: The leather used by BMW is a high-quality, state-of-the art processed natural product,
whose quality level lasts for years with the appropriate care. Follow the instructions in the
Service Information (bulletin) 51 02 02 (834) and the instructions in the Owner's Handbook
on BMW Premium Leather Care. The BMW approved leather cleaners and care sets are to be used.
To maintain the high-qualtity leather prepared by BMW even after damage without replacement of the
complete seat cover or the interior covering, BMW offers a leather repair kit. To perform leather repairs the
”BMW appearance repair/ interior repair" Aftersales training is recommended.
Advantages for the customer:Part replacement can be avoided with cost-effective repairs of minor damage.
Advantages for the BMW dealer:Professional leather repair can increase the value of a vehicle. A repair is
possible in approx. 60 to 80 minutes. Restrictions on the repair are with damages to seams.
Caution!
The marked ”airbag seam” must not be repaired!
Despite very good results, new part quality can not be achieved. For damages which are the fault of the
customer, it is advisable to exclude the warranty claims for this repair before applying the leather repair.
A repair is only carried out in justified case of customer complaint.
Note:
The leather repair requires permanent training and a high degree of manual dexterity. In order to
meet the situations in all BMW Service authorised workshops, there are two application variants
offered for optimal use:
1. Just as bodyshops and paint shops are used for body damages, there is also the
possibility here, to engage a qualified local supplier for the leather repair.
POS Polsterservice GmbH is recommended in Germany.
Contact data:
POS Polsterservice GmbH
Mühlenpfad 2-4
53547 Hausen-Solscheid
Telephone: +49 (0) 2638 / 921-700 (for German, Austria and Switzerland)
Telephone: +49 (0) 5828 / 80755 (for Netherlands, Belgium and Luxembourg)
E-mail: vertrieb@polsterservice.de
E-mail: jvanderveen@polsterservice.de (for the Netherlands, Belgium and Luxembourg)
Internet: http://www.polsterservice.de
2. Use of the BMW leather repair set and its application after participating in the recommended
Aftersales training ”BMW appearance repair/ interior repair”.
The following fault patterns belong to the most frequent complaints for leather upholstery:
1. Discolouration and dirt contamination
2. Wear
3. Scratches
4. Tears and cuts
5. Open seams
6. Ripples
7. Creasing (with and without rollover)
8. Leatherette crack
Affectedvehicles:All BMW and MINI vehicles with leather option

Measure: 1. Discolouration and dirt contamination
Clothing (especially jeans and leather
clothing in damp condition) can bleed
colours onto the leather. Especially
subject to this are special light coloured
interior options
To prevent the leather from discolouration and dirt contamination, regular leather care is required (also refer to
SI 510202834 and notes in the Owner's Handbook on leather care).
Using the care and cleaning set approved by BMW, these discoulorations and dirt contaminations can be
removed in most cases. If is no longer the case, because it is at an advanced stage, the dirt contamination
has already penetrated into the leather.
Caution!
Work using BMW leather care kit is not reimbursed by the warranty as this is a cleaning and care
operation.
Discolouration and dirt contamination resulting from lack of care are not a case of defect of the
leather. In case of a customer complaint defective material must be proven and if necessary the
part replaced.
2. Wear
Wear marks, e.g. on the seat bead, can occur by continual
mechanical stress and the used geometries.
Regular care keeps the leather soft and protects from wear.
The effected location can be repaired with the aid of the BMW leather repair kit.
Only for repeated customer complaints is the effected part to be replaced.
Caution!
If again waiting for a repair is not successful, in case of repeated customer complaints the effected
part must be repaired. The invoicing is to the warranty.
See billing procedures!
3. Scratches
The leather surface is like scales. Obvious damages to the
leather surface caused by pointed objects such as, belt,
buttons, keys or zippers.
The fault pattern presents no product defect. The effected location can be repaired with the aid of the BMW
leather repair kit.
4. Tears and cuts

Obvious completely cut leather caused by sharp objects, such
as keys or knives.
The fault pattern presents no product defect. Replacement of cover necessary.
5. Open seams
Open seams -general
Damaged or open seams caused by pointed or sharp objects.
The effected spot can be repaired more economically by an external service provider.
Caution!
For damaged airbag seams (sewed in) on the cover of the seat backrest or the door trim panel,
the effected part must be replaced.
See billing procedures!
Open "airbag seam"

Caution!
The marked ”airbag seam” must not be repaired!
6. Ripples
A ripple in the surface is completely desired to emphasise the natural character of the leather. The ripples
in the leather can change due to fluctuations in temperature and humidity.
In case of customer complaints, the customer should be advised of the natural character and design of the
leather upholstery. A treatment of the effected spot has no purpose.
7. creasing
Creasing without rollover of material
Depending on the cover design, the natural leather qualities
(stretch) and the individual type of entering the vehicle,
permanent creasing (without rollover of the material) of the
seat cover can occur on the seat surface
Creasing with rollover of material

Heavy creasing (with rollover of material) on the seat surface is
caused by extreme stress.
Caution!
a. Creasing without rollover of material is not a defect of the leather. Part replacement on
warranty is not justified.
b. For creasing with rollover of material, in the case of customer complaint the effected part
must be replaced on warranty.
To compensate for possible colour variations, the adjacent leather surfaces must be
treated with the leather care kit.
8. Leatherette crack
Surface cracks in leatherette.
The underlying fabric structure is visible.
In case of customer complaints the effected part is to be replaced on warranty.
Pro-cedure: Effective immediately measures for leather complaints will be decided based on damage
images.
1. In case of customer complaint, check if the leather surface can be repaired by care measures.
For the procedure, refer to Service Information (bulletin) 51 02 02 (834).
2. If there is damage of the leather in the case of customer complaint, for warranty claims convincing digital
photos with the following contents must be made (similar to a paint complaint).
Total image of the damage location
Detail image of the damage location
Display the scale for size of damage spot with a ruler or a coin as reference
Diagram and description of the damage location is retained in the vehicle records.
Acceptance of warranty costs depends on the evaluation of the leather damage.
3. Repair damaged spots according to the recommendations in the BMW appearance repair/interior repair
Aftersales training or by a qualified service provider.
Billing procedures:
Caution!
The fault pattern 1 (Dirt contamination, discolouration), 3 (Scratches), 4 (Tears and cuts) and
6 (Ripples) are not a product defect of the leather. Part replacement on warranty is not justified.
Warranty
For leather repair work in case of warranty (e.g. wear) the invoicing is made according to working time (AZ)
under the following job numbers:
BMW appearance repair passenger compartmentJob number: 52 99 010
MINI appearance repair passenger compartmentJob number: 52 99 020
Material and labour costs incurred can be claimed through the usual warranty channels subject to current
warranty terms.
Parts: Part number Description Quantity
83 12 0 411 371(USA only) Leather care kit 1
83 12 0 415 497(Canada BMW Premium Leather Care 1
only
83 12 9 407 907 Leather cleaning foam 1
83 19 2 162 184 Leather repair kit 1
Note:
52 02 00 (616)
Sport seat causes cracking noises
E46
Complaint: Sport seat causes cracking noises when corning or on load change.
Cause: The seat cushion shell has a small amount of play on the side seat inclination adjustment
mechanism.
Affected E46 with option 481 (sports seats with electric and mechanical adjustment)
vehicles: Manufacturing period: start of series production until September 2001
Remedy: An O-ring must be fitted on both sides between the side section of the seat cushion shell
and the bearing point of the inclination adjustment.
Procedure:
1. Move the seat to the rearmost fore/aft setting to ensure that there is sufficient space in
the footwell.
2. Move the seat height adjustment to the uppermost position.
3. Lever the seat inclination adjustment to the uppermost position.
4. Remove the bolt for the seat inclination adjustment shaft on both sides (see Fig. 1).
Fig. 1
5. An O-ring (1.8 x 8.0) must be fitted on both sides between the side section of the seat cushion shell and
the bearing point. To do this, bend the side sections out slightly with a screwdriver (see Fig. 2).
Fig. 2
6. Bend the side sections back and refit the removed bolts (see Fig. 3)
Fig. 3
Parts:
07 11 9 906 356 O-ring (1.8 x 1.8) 2 for each seat
Fit O-ring in side section of seat cushion shell.
Labour 3 FRUs
Warranty type 1

Reimbursement is limited to 36 months / 100,000Â km and only possible until February 2005.
54 01 98 (324)
Sliding/tilting sunroof - changed function
E46
Situation: The description in the Owner's Handbook states that when the sliding/tilting sunroof is
raised and the switch is briefly pressed to the ”open” position, the sunroof will move into
the ”sliding/tilting sunroof open” end position.
This description is incorrect.
The Owner's Handbook will be corrected at the next revision.
Affected All E46 vehicles from start of series production.
vehicles:
Procedure: To initiate the function ”open sunroof” when the sliding/tilting sunroof is raised, the sunroof
must first be manually closed via the switch. The sunroof can then be opened via the tip
function.
The vehicles do not therefore display a product defect.
Please pass this information on to your Sales Department so that customers can be informed prior to delivery
of their vehicles.
54 03 03 (023)
Sliding/tilting sunroof cassette - repair solution
E46/2, E46/3, E46/4, E46/5
Complaint: Failure of sliding/tilting sunroof and/or roof panel headlining.
Cause:
Slide elements on left of sunroof visor broken.
Driver in casing bent, broken or strong vertical clearance.
Important!
The driver may be slightly out of line with the left-hand sliding member.
Affected vehicles:E46 with sliding/tilting sunroof (option 403)

Manufacturing period: from start of series production until August 2003
Remedy: In the event of a customer complaint, there is now a repair solution, so that if the driver is
damaged, the complete sliding/tilting sunroof casing does not have to be replaced.
Note:
Modified drivers and a modified roof panel headlining with sliding members have been in use in
series production since September 2003.
Procedure: Remove the glass sliding/tilting sunroof cover.
Check the driver:
Check the driver for damage.
If no damage is visible on the driver, check the vertical clearance as follows:
Carefully lift the driver (2).

Use the feeler gauge (1) to check the vertical clearance
between the driver (2) and the guide rail (3).
Necessary measures after checking the driver:
Test result Necessary measures

Driver not damaged and vertical Check sunroof visor as well as left
clearance less than 2.5 mm
and right slide elements.
Please refer to following matrix for
necessary components and repair
instructions.
Driver bent, broken or vertical clearance Install a modified driver and roof panel
equal to or greater than 2.5 mm headlining with new sliding members
Please refer to following matrix for necessary
components and repair instructions.
Matrix for selecting necessary components and repair instructions:
Damaged component Required Repair

component instructions
Slide Slide Driver Sunroof
element(s), element(s), visor
left right
X Slide element(s), left Enclosure 1
X Sunroof visor + Enclosure 2
2 slide elements, left
X X Sunroof visor + Enclosure 2
2 slide elements, left
X Slide element(s), Enclosure 2
right
X Sunroof visor Enclosure 3
+ repair kit
X X Sunroof visor Enclosure 3
+ repair kit
X X Sunroof visor Enclosure 3
+ repair kit
X X X Sunroof visor Enclosure 3
+ repair kit
Parts: Description Part number Quantity

per pack
Modified roof panel headlining Depending on colour 1
(introduction from 08/2003) variant - please refer to
Electronic Parts Catalogue
including 2 slide elements, right (EPC)
Repair kit E46/2 54 10 7 134 073 1
Repair kit E46/3/4 54 10 7 134 072 1
Repair kit E46/5 54 13 7 134 544 1
Old slide element, left 54 13 8 246 027 1
(used up to 09/2003)
New slide element, left 54 13 7 134 516 1
(used as from 09/2003)
Slide element, right 54 13 8 246 025 1
As part of workshop visit:
Replacing one slide element, left

Labour 5 FRUs; E46/2 (Coupe)

5 FRUs; E46/3 (Touring)
5 FRUs; E46/4 (Saloon)
5 FRUs; E46/5 (Compact)
Replacing two slide elements, left

Replacing two slide elements, right

Replacing sunroof visor

Replacing sunroof visor and driver

Without additional repair order:
Replacing one slide element, left


Replacing two slide elements, left

Replacing two slide elements, right

Replacing sunroof visor

Replacing sunroof visor and driver

Warranty type 1

Reimbursement is limited to 36 months/100,000 km and only possible until August 2006.

61 07 02 (875)
Battery master document
All model series
Situation: The electrical system of BMW vehicles has been subject to an ongoing development
process over the last few years. This has led to increased demands being placed on the
battery. This document summarises all important information about how the battery should
be handled in the dealership.
Procedure: The complaint ”flat battery” can have various causes, most of which do not concern the
battery itself. For that reason, replacing the battery will only very rarely provide a
permanent solution to the problem. The cause must be properly analysed in order to
perform a repair that actually rectifies the cause.
Below you will find list of the available auxiliary materials. These must be worked through step-by-step to
investigate the problem. The documents listed can be accessed via hotspots.
1. Fault (cause) analysis (energy diagnosis)
Fundamentally, the following causes are possible for a breakdown resulting from a flat battery or problems in
the vehicle's electrical power supply:
Vehicle faults
Battery defective / alternator fault
Vehicle does not ”go to sleep”
Vehicle keeps being woken up
Excessive standby current
Operating error
Side lights/parking lights/hazard warning flashers left on too long
Terminal R/15 left on too long
Unreasonable driving/usage profile
An unreasonable driving profile (e.g. extremely short distances) or an unreasonable usage profile (.e.g. too
long immobilisation period, use of auxiliary consumers) represents a very frequent cause of running down the
battery without there being a fault with the vehicle or battery.
If in these cases the battery is not charged sufficiently during driving, a charger must be connected during the
immobilisation period (recommended chargers with cable permanently connected to battery, see BMW Group
Parts).
Attention!
Do not connect the chargers to the 12 V charging socket on the vehicle side. The vehicle electrical system is
thus prevented from "going to sleep" and the battery from being discharged.
The installation of a larger battery or an AGM battery can be used to rectify this (if an AGM battery has not yet
been installed).
Customers who have no option to connect a charger to their vehicle during the immobilisation period are
recommended, as the only alternative in reaching a state of charge that is too low, to travel distances of at
least 10 km.
For the following vehicles the energy diagnosis test procedure must be worked through in the event of
the complaint “flat battery”:
E65, E66, E67 from model year 03/2004,
E60, E61, E63, E64, E70, E71, E72, E81, E82, E84, E87, E88, E89, E90, E91, E92, E93,
All F Series from F01,
BMW i
All MINIs from R55,
RR04,
Note:
The aim of energy diagnosis is to identify the most probable cause for a breakdown caused by a
flat battery or for problems in the vehicle's electrical power supply. The causes listed above are
stored in energy diagnosis.
To enable the applicant to use the correct defect code, make sure that both the customer's
statement and the diagnosis results are adequately documented. These must be made available
to the applicant.
Text search in ISTA or path: Function Structure > 03 Body > Voltage supply > Energy diagnosis
For all other model series:
For series without energy diagnosis, the customer shall be interviewed to make sure the operator errors
described above can be ruled out as the cause of the battery discharging.
An on-board diagnosis is available to evaluate the battery condition of vehicles with intelligent battery
sensor (IBS) or battery electronics (lithium ion battery):
All BMW and MINI F series from series introduction
Exception: F01, F02, F03 up to 09/2010, F04
BMW i
RR04
The following criteria are analysed to evaluate state of charge:

Capacity loss
Charge balance
Complete discharges
Operational energy capacity through automatic engine start-stop function (MSA)
Water loss
The battery condition is determined for the following vehicles with intelligent battery sensor (IBS)by
evaluation of the operational energy capacity and the voltage dip at engine start:
all BMW E-series
F01, F02, F03 up to 09/2010, F04
all MINI R-series
For vehicles with automatic engine start-stop system, if this function is not fully available:
Important!
The prerequisite for invoicing a battery through the warranty channel is to work through the test
module.
Energy diagnosis through to the diagnosis result:
Displaying of cause
Displaying of help instructions
Displaying of corresponding diagnosis code
Exceptions are:
Obvious battery damage and leakage
Use the correct defect code in such situations (61 21 00 49 or 61 21 00 01).
Use of BMW Group Mobile Service and battery replacement on site to restore customer mobility as
quickly as possible.
2. Measure closed-circuit current

Standby current check of the 12 V battery
BMW diagnosis system (functional description):
E38, E39, E46, E53, E83, E85,
Path: Complete vehicle > Electric motor > Voltage and current control > Voltage and current supply > Standby
current measurement
E65, E66, E67,

Path: Complete vehicle > Body > Voltage supply > Voltage and current supply > Standby current
measurement > Off-load current diagnosis
BMW i
All MINIs from R55,
RR04,
Path: Service functions > Body > Voltage supply > Standby current
3. Check alternator
Diagnosis system (functional description):
All except E65, E66, E67,

Path: Complete vehicle > Electric motor > Voltage and current control > Voltage and current generation
E65, E66, E67,

Path: Complete vehicle > Body > Voltage supply > Alternator
4. Battery replacement
In the following vehicles the new battery needs to be registered via the diagnosis system:
Always:
E65, E66, E67,
F80, F82, F83,
Providing an intelligent battery sensor (IBS) is fitted (depends on vehicle equipment):
BMW i
All MINIs from R55,
RR04,
Important!
If the new battery is not registered, incorrect readings may appear in the display of the on-board
computer due to previous data in the power management system (check control message
"Recharge battery" appears even though the battery is new).
Only AGM batteries should be installed in the following vehicles:

E65, E66, E67,
F01, F02, F03, F04, F06, F07, F10, F11, F12, F13, F18,
BMW i
Vehicles with auxiliary heater (SA536), intelligent generator control or automatic engine start-stop
function.
Only lithium ion batteries should be installed in the following vehicles:

F80, F82, F83
5. Battery charging
5.1 Charging the lead-acid-battery or the AGM battery
The battery may only be recharged by means of chargers that have been approved by BMW and that
have a constant charging voltage of 14.8 V.
If possible, the battery temperature should be between 15 °C and 25 °C during charging. Under these
preconditions, the battery is adequately charged when the charge current drops below 2.5 amps.
If the battery is recharged at lower temperatures, the process should not be ended until the charge
current drops below 1.5 amps.
On vehicles with IBS, recharging the battery directly at the battery terminals could lead to a
misinterpretation of the battery condition and even unwanted Check Control messages or fault entries.
If the battery is recharged while it is installed, it must be recharged using the jump start terminal points,
whenever jump start terminal points are provided in the engine compartment. Only then can you be sure
that recharging is correctly recognised by the vehicle electronics on vehicles with intelligent battery
sensor (IBS).
Exception: MINI from R55: These vehicles do not have any jump start terminal points in the engine
compartment.
On these vehicles, the positive terminal of the battery charger must be directly connected to the battery.
On vehicles with a petrol engine, the negative terminal can be connected to the lifting eye (suspension
lug) on the transmission and on vehicles with diesel engines to a flange on the engine bearing block on
the engine.
5.2 Charging the lithium ion battery

Important!
The charging voltage that is generated by existing chargers that are designed for the lead-acid or
AGM battery is too high for the lithium ion battery.
This excessive charging voltage may in some cases result in that the separating switch of the
lithium ion battery will be opened. This does not damage the lithium ion battery. The separator
switch will close again when a charging voltage of < 14 V is applied at the battery terminals.
Before charging a lithium ion battery, adjust the charging voltage of existing charger adapters
once.
Do not charge lithium ion battery when temperature is below 5 °C!
The lithium ion battery can be charged via the jump start terminal points in the engine compartment as
well as directly on the battery terminals.
6. Charging the high-voltage battery

Charge high-voltage battery E72, F04
Notes on charging the high-voltage battery on standing vehicles E72, F04
(new and used cars)
Notes on charging the high-voltage battery on standing vehicles F01H, F02H, F10H, F30H
(new and used cars)
7. Notes on handling the high-voltage battery in the workshop F01H, F02H, F10H, F30H
Eighth Additional publications of the subject of ”Batteries”

AGM battery - brief component description
Notes on AGM battery
Information on intelligent battery sensor (IBS)
Notes on lithium ion battery
Notes on battery electronics (lithium ion battery)
Battery recharging intervals for stationary vehicles, battery charging 12-V battery, high-voltage
calendar and battery tag battery unit
Battery log form (not for USA)
Notes on charging batteriesE65
Electronic battery master switch - all model series
Battery positive terminal with battery in luggage compartment, E36
System battery discharges, E38/3
Replace system battery, E38 M73
Checking electrical connection for secondary air pump, Z3
61 03 98 (387)
All models
12V battery
All vehicles:
12 weeks


N.B.:
charging calendar.

51 01 99 (392)
Windscreen wipers making noises
All models
Complaint: Windscreen wiper blades scraping.
Wiping area is not properly wiped.
Cause:
- When the windscreen is dirty and greasy, the windscreen wipers increasingly tend to scrape.
- The wiper arm contact angle is not set correctly.
- Wiper blade faulty - worn
Affected All models
vehicles:
Remedy: Check for all of the causes listed above.
Procedure:
- Clean the windscreen and wiper blades with BMW silicone remover.
- Check and if necessary adjust the contact angle of the wiper blades to the windscreen using the special
tool.
See Repair Instructions 61 61 010.
- Check the wiper blades for damage. Replace them if necessary.

Important notes:
- Only disassemble the wiper arms using the appropriate special puller.
See Repair Instructions 61 61 100.
- Broken wiper arms are not covered by the vehicle warranty.

Important note for the German market:
- Wiper blades must be cleaned and sent in in the original packaging, otherwise they cannot be
replaced under warranty.
Parts: Order number for special tools
Description Order number Vehicle type

Wiper arm puller 61 6 060 all model series
Wiper arm puller 61 6 000 E36, E38, E39
Contact angle 00 9 230 E36, E38, E39
test gauge
Contact angle 00 9 331 E46
test gauge
Wiper arm 00 9 261 / 00 9 262 E39
setting tool
Wiper arm 00 9 220 E36, E38
setting tool
Wiper arm 00 9 332 / 00 9 333 E46
setting tool
Silicone remover 83 19 9 407 906
61 03 01 (753)
Automatic driving lights in bright conditions switched on
E39, E46, E53, E65, E66, E85, R50, R53 with rain sensor and automatic driving
lights control (optional equipment 521)
Complaint: When the ”Automatic driving lights control” setting is selected, the customer perceives the
driving lights to come on unnecessarily in bright conditions or take a long time to switch off
again.This can often be the case in clear, sunny weather (cloudless sky).
Cause: Current technology is unable to reproduce the light sensitivity of the human eye in the
driving light sensor in all situations.
To ensure reliable activation of the driving lights at the onset of dusk, a sensible driving
light sensor interpretation setting was applied in the factory. From a human point of view, this can result in the
driving lights being switched on too early or taking too long to switch off in bright conditions.
There is no fault with the driving light sensor. A part replacement would make no difference and must not
be performed.
Affectedvehicles:E39, E46, E53, E65, E66, E85, R50, R53 with rain sensor and automatic driving lights
control (optional equipment 521)Production period: E39, E46, E53, R50, R53 from
September 2001Production period: E65, E66, E85 from series introduction
Procedure: In the event of a complaint, explain the situation to the customer.
If the customer would like the automatic driving lights control behaviour modified, then this
may be adjusted:E65, E66, E85 - in the CIP program (encoding, individualisation,
programming)E39, E46, E53, R50, R53 - in the ”Car Memory” program
Invoicing under warranty is not permitted.
12 01 00 (534)
Battery charge warning light flickers
E46 / M47, M57
Complaint: On the above vehicles, the battery charge warning light can intermittently flicker of light up
briefly while the vehicle is being driven.
Cause: Faults in the fault recognition logic circuits of the alternator regulator lead to intermittent
actuation of the battery charge warning light. The charge level of the vehicle is not affected
and there is no fault in the instrument cluster.
Affected E46 with M47/M57
Remedy: From April 2000, vehicles will be equipped in series production with an additional circuit
which prevents the battery charge warning light from being incorrectly actuated.
In case of customer complaint, an adapter cable must be retrofitted to the instrument
cluster.
Procedure: Remove the complete instrument cluster
(please refer to Repair Instructions for E46, job item no. 62 21 000).
Remove the connector on the right of the instrument cluster (26-pin, black).
Note:
When working with the wiring harness disconnected, take care to ensure that no electrostatic charge comes
into contact with the connectors.
Fig. 1:
Connector on instrument cluster
Install the adapter cable between the vehicle wiring harness and the instrument cluster.
Note:
The entire plug connector must be mantled in foam after assembly.
Fig. 2:
Foam mantle around plug connector
Position the plug connector between the adapter cable and the wiring harness centrally in the opening in the
air duct behind the instrument cluster.
Fig. 3:
Routing the adapter cable
Note:
When installing the instrument cluster, take care to ensure that the plug connector between the vehicle wiring
harness and the adapter cable is positioned in such a way that it will not cause any rattling noises while the
vehicle is being driven.
After installation, there must not be a gap between the instrument panel and the instrument cluster.
Parts: Adapter cable: Part no. 12 51 7 786 936
12 51 92 87 00
Refit adapter cable:
Labour 5 FRUs
Warranty type 1

61 07 02 (875)
Battery master document
All model series
Situation: The electrical system of BMW vehicles has been subject to an ongoing development
process over the last few years. This has led to increased demands being placed on the
battery. This document summarises all important information about how the battery should
be handled in the dealership.
Procedure: The complaint ”flat battery” can have various causes, most of which do not concern the
battery itself. For that reason, replacing the battery will only very rarely provide a
permanent solution to the problem. The cause must be properly analysed in order to
perform a repair that actually rectifies the cause.
Below you will find list of the available auxiliary materials. These must be worked through step-by-step to
investigate the problem. The documents listed can be accessed via hotspots.
1. Fault (cause) analysis (energy diagnosis)
Fundamentally, the following causes are possible for a breakdown resulting from a flat battery or problems in
the vehicle's electrical power supply:
Vehicle faults
Battery defective / alternator fault
Vehicle does not ”go to sleep”
Vehicle keeps being woken up
Excessive standby current
Operating error
Side lights/parking lights/hazard warning flashers left on too long
Terminal R/15 left on too long
Unreasonable driving/usage profile
An unreasonable driving profile (e.g. extremely short distances) or an unreasonable usage profile (.e.g. too
long immobilisation period, use of auxiliary consumers) represents a very frequent cause of running down the
battery without there being a fault with the vehicle or battery.
If in these cases the battery is not charged sufficiently during driving, a charger must be connected during the
immobilisation period (recommended chargers with cable permanently connected to battery, see BMW Group
Parts).
Attention!
Do not connect the chargers to the 12 V charging socket on the vehicle side. The vehicle electrical system is
thus prevented from "going to sleep" and the battery from being discharged.
The installation of a larger battery or an AGM battery can be used to rectify this (if an AGM battery has not yet
been installed).
Customers who have no option to connect a charger to their vehicle during the immobilisation period are
recommended, as the only alternative in reaching a state of charge that is too low, to travel distances of at
least 10 km.
For the following vehicles the energy diagnosis test procedure must be worked through in the event of
the complaint “flat battery”:
E65, E66, E67 from model year 03/2004,
BMW i
All MINIs from R55,
RR04,
Note:
The aim of energy diagnosis is to identify the most probable cause for a breakdown caused by a
flat battery or for problems in the vehicle's electrical power supply. The causes listed above are
stored in energy diagnosis.
To enable the applicant to use the correct defect code, make sure that both the customer's
statement and the diagnosis results are adequately documented. These must be made available
to the applicant.
Text search in ISTA or path: Function Structure > 03 Body > Voltage supply > Energy diagnosis
For all other model series:
For series without energy diagnosis, the customer shall be interviewed to make sure the operator errors
described above can be ruled out as the cause of the battery discharging.
An on-board diagnosis is available to evaluate the battery condition of vehicles with intelligent battery
sensor (IBS) or battery electronics (lithium ion battery):
All BMW and MINI F series from series introduction
Exception: F01, F02, F03 up to 09/2010, F04
BMW i
RR04
The following criteria are analysed to evaluate state of charge:

Capacity loss
Charge balance
Complete discharges
Operational energy capacity through automatic engine start-stop function (MSA)
Water loss
The battery condition is determined for the following vehicles with intelligent battery sensor (IBS)by
evaluation of the operational energy capacity and the voltage dip at engine start:
all BMW E-series
F01, F02, F03 up to 09/2010, F04
all MINI R-series
For vehicles with automatic engine start-stop system, if this function is not fully available:
Important!
The prerequisite for invoicing a battery through the warranty channel is to work through the test
module.
Energy diagnosis through to the diagnosis result:
Displaying of cause
Displaying of help instructions
Displaying of corresponding diagnosis code
Exceptions are:
Obvious battery damage and leakage
Use the correct defect code in such situations (61 21 00 49 or 61 21 00 01).
Use of BMW Group Mobile Service and battery replacement on site to restore customer mobility as
quickly as possible.
2. Measure closed-circuit current

Standby current check of the 12 V battery
BMW diagnosis system (functional description):
E38, E39, E46, E53, E83, E85,
Path: Complete vehicle > Electric motor > Voltage and current control > Voltage and current supply > Standby
current measurement
E65, E66, E67,

Path: Complete vehicle > Body > Voltage supply > Voltage and current supply > Standby current
measurement > Off-load current diagnosis
BMW i
All MINIs from R55,
RR04,
Path: Service functions > Body > Voltage supply > Standby current
3. Check alternator
Diagnosis system (functional description):
All except E65, E66, E67,

Path: Complete vehicle > Electric motor > Voltage and current control > Voltage and current generation
E65, E66, E67,

Path: Complete vehicle > Body > Voltage supply > Alternator
4. Battery replacement
In the following vehicles the new battery needs to be registered via the diagnosis system:
Always:
E65, E66, E67,
F80, F82, F83,
Providing an intelligent battery sensor (IBS) is fitted (depends on vehicle equipment):
BMW i
All MINIs from R55,
RR04,
Important!
If the new battery is not registered, incorrect readings may appear in the display of the on-board
computer due to previous data in the power management system (check control message
"Recharge battery" appears even though the battery is new).
Only AGM batteries should be installed in the following vehicles:

E65, E66, E67,
F01, F02, F03, F04, F06, F07, F10, F11, F12, F13, F18,
BMW i
Vehicles with auxiliary heater (SA536), intelligent generator control or automatic engine start-stop
function.
Only lithium ion batteries should be installed in the following vehicles:

F80, F82, F83
5. Battery charging
5.1 Charging the lead-acid-battery or the AGM battery
If the battery is recharged at lower temperatures, the process should not be ended until the charge
current drops below 1.5 amps.
On vehicles with IBS, recharging the battery directly at the battery terminals could lead to a
misinterpretation of the battery condition and even unwanted Check Control messages or fault entries.
If the battery is recharged while it is installed, it must be recharged using the jump start terminal points,
whenever jump start terminal points are provided in the engine compartment. Only then can you be sure
that recharging is correctly recognised by the vehicle electronics on vehicles with intelligent battery
sensor (IBS).
Exception: MINI from R55: These vehicles do not have any jump start terminal points in the engine
compartment.
On these vehicles, the positive terminal of the battery charger must be directly connected to the battery.
On vehicles with a petrol engine, the negative terminal can be connected to the lifting eye (suspension
lug) on the transmission and on vehicles with diesel engines to a flange on the engine bearing block on
the engine.
5.2 Charging the lithium ion battery

Important!
The charging voltage that is generated by existing chargers that are designed for the lead-acid or
AGM battery is too high for the lithium ion battery.
This excessive charging voltage may in some cases result in that the separating switch of the
lithium ion battery will be opened. This does not damage the lithium ion battery. The separator
switch will close again when a charging voltage of < 14 V is applied at the battery terminals.
Before charging a lithium ion battery, adjust the charging voltage of existing charger adapters
once.
Do not charge lithium ion battery when temperature is below 5 °C!
The lithium ion battery can be charged via the jump start terminal points in the engine compartment as
well as directly on the battery terminals.
6. Charging the high-voltage battery

Charge high-voltage battery E72, F04
Notes on charging the high-voltage battery on standing vehicles E72, F04
(new and used cars)
Notes on charging the high-voltage battery on standing vehicles F01H, F02H, F10H, F30H
(new and used cars)
7. Notes on handling the high-voltage battery in the workshop F01H, F02H, F10H, F30H
Eighth Additional publications of the subject of ”Batteries”

AGM battery - brief component description
Notes on AGM battery
Information on intelligent battery sensor (IBS)
Notes on lithium ion battery
Notes on battery electronics (lithium ion battery)
Battery recharging intervals for stationary vehicles, battery charging 12-V battery, high-voltage
calendar and battery tag battery unit
Battery log form (not for USA)
Notes on charging batteriesE65
Electronic battery master switch - all model series
Battery positive terminal with battery in luggage compartment, E36
System battery discharges, E38/3
Replace system battery, E38 M73
Checking electrical connection for secondary air pump, Z3
61 03 98 (387)
All models
12V battery
All vehicles:
12 weeks


N.B.:
charging calendar.

61 02 01 (741)
Brightness variations with seat heating switched on
E46
Complaint: If seat heating on both sides (driver's and passenger) is switched on, the dipped
headlights, high-beam headlights and instrument lighting vary intermittently in brightness
with a frequency of approx. one Hertz.
Cause: Voltage drops in the vehicle's electrical system.
Affected E46 with seat heating (option 494).

vehicles: Manufacturing period: from September 1999 until June 2001
Procedure: In case of customer complaint, check whether the customer's description can be
confirmed. To do this, with the engine running, switch on seat heating on both sides
(maximum heating level) and switch on the exterior lights. After a few minutes, when the
maximum seat temperature has been reached, the seat heating will go into regulation mode.
If the brightness variations can then be verified, replace the switch unit in the centre console.
Please refer to Repair Instructions ”Replacing switch unit in oddments compartment”
RA 61 31 058.
Centre console as per Electronic Parts 1
switch panel Catalogue (EPC)
Within the scope of a visit to the workshop
Replace centre console switch panel:
Labour 3 FRUs
In case of order without additional repair operations

Replace centre console switch panel:
Labour 5 FRUs
Warranty type 1

Reimbursement is limited to 36 months/100,000 km and only possible until June 2004.

61 04 01 (757)
Dipped headlights remain on
E46
Complaint: The dipped headlights stay on when the ignition is ”on” and the light switch is set to ”0”. At
the same time, the instrument lighting, the tail lights and the number-plate light remain on.
”Control unit fault” is stored in the fault memory of the central light switch (LSZ).
Cause: Internal defect in the central light switch.
Affected E46
vehicles: Manufacturing period: February 2000 until November 2000
Procedure: In case of customer complaint, the central light switch must be replaced.
Please refer to repair instructions ”Removing and installing / replacing control panel for light
switching unit”
RA 61 31 036
Light switching unit as per Electronic Parts 1
Catalogue (EPC)
Within the scope of a visit to the workshop - Read off and clear fault memory and
replace light switching unit:
Labour 4 FRUs
In case of order without additional repair operations - Read off and clear fault memory
and replace light switching unit:
Labour 6 FRUs
Warranty type 1

Reimbursement is limited to 36 months/100,000 km and only possible until November 2003.
61 05 00 (630)
Exterior mirror reset imprecise
E46
Complaint: The passenger-side exterior mirror no longer returns to its original position after the
reverse-gear tilt-down function (automatic parking function). The position changes
upwards by approx. 2° after each operation. The passenger-side exterior mirror returns to
its original position when the corresponding seat memory position switch is pressed.
Cause: A precise reset is not possible due to mechanical deviations in the mirror mechanism.
Affected E46 with seat memory for driver's side (option 459)
vehicles: Manufacturing period:
coupé, saloon: September 1999 to September 2000
touring: June 1999 to September 2000
convertible: December 1999 to September 2000
Procedure: In case of customer complaint, replace the passenger-side mirror memory control unit.
Install a control unit with software 2.0 or later. The software has been modified to
compensate for the mechanical tolerance in the mirror mechanism. To remove the control
unit, first remove the passenger door trim. Please refer to Repair Instructions ”Removing and installing left or
right door trim”,
Repair Instructions 51 41 000.
Parts:
Mirror memory control unit 61 35 6 913 364 1
As part of a visit to the workshop
Replace the passenger-side mirror memory control unit:
Labour 5 FRUs saloon, touring

6 FRUs coupé, convertible
Replace passenger-side mirror memory control unit:
Labour 7 FRUs
Warranty type 1

Reimbursement is only possible until June 2002 and limited to
36 months / 100,000 km.
61 02 02 (808)
Radio station or CD track jumps when volume button is pressed
E39, E46, E53
Complaint: When the volume control button on the multi-function leather sports steering wheel is
pressed, the radio station sometimes jumps to the next or the previous station in the
memory, or if the unit is in CD mode, it will jump to the next or the previous track.
Cause: Faulty connection due to excessive component tolerance in the switch block in the
protective cap of the multi-function sports steering wheel.
Affected E39, E46, E53 with leather sports steering wheel (option 255) and with multi-function
vehicles: facility, including cruise control (option 249)
E39, E46 February 2001 to August 2001.
E53 February 2001 to September 2001.
Procedure: In case of customer complaint, check to see if the fault can be reproduced. If the fault
pattern can be reproduced, replace the protective cap of the multi-function sports steering
wheel. Please refer to Repair Instructions ”Replacing switches in sports steering wheel
(smart airbag)” RA 61 31 228.
Parts:
Multi-function sports 61 31 6 904 467 1
steering wheel protective
cap
Within the scope of a visit to the workshop -
replace protective cap on multi-function sports steering wheel:
Labour 3 FRUs
E46 compact, E46 touring, E46 saloon 4-cyl. petrol, E46 coupé 4-cyl. petrol
4 FRUS
E46 saloon diesel + 6-cylinder petrol, E46 coupé 6-cyl., E46 convertible
3 FRUs E39 saloon
4 FRUS E39 touring, M5
4 FRUs E53
In the case of a job not involving additional repair work -
replace protective cap on multi-function sports steering wheel:
Labour 5 FRUs E46

5 FRUs E39
6 FRUs E53
Warranty type 1

Reimbursement is limited to 36 months/100,000 km and only possible until September 2004.
61 02 00 (541)
Rain sensor (AIC): Diverse malfunctions
E38, E39, E46
Complaint: The following malfunctions are known in the windscreen wiper control with activated rain
sensor (Automatic Interval Control / AIC):
1. The windscreen wiper wipes continuously or in an uncontrolled fashion. This malfunction occurs
sporadically.
2. The sensitivity of the rain sensor cannot be adjusted.
3. Control of the windscreen wiper via the rain sensor fails intermittently. The control works again properly
after switching the ignition (terminal 15) off and back on again.
4. The windscreen wiper remains off for a brief period of time when it is switched down from normal wiper
speed (wiper switch position 2 or 3) to rain sensor (wiper switch position 1).
5. The windscreen wiper switches on without reason when the vehicle moves between shade and sunlight
(e.g. when driving out of a tunnel into the sun).
6. The windscreen wiper wipes the windscreen four or five times when the rain sensor is activated. After
this, the rain sensor control of the windscreen wiper no longer works.
7. The windscreen wiper does not stop in the end position but rather it moves approx. 10° to 15° from this
position and then stops.
If the rain sensor fails, the windscreen wiper control will operate in the same way as on a vehicle without rain
sensor installed, i.e. in normal intermittent wipe mode.
Cause: Possible cause for fault patterns 1 to 5:
Software errors in rain sensor
Possible cause for fault patterns 6 to 7:
Windscreen wiper double relay defective.
Note:
Bubbles forming in the area of the rain sensor are permissible and do not as a rule affect the functionality of
the rain sensor.
Affected vehicles:E38, E39, E46 with rain sensor
Manufacturing period: Start of series production until January 2000.
Depending on the model concerned, the rain sensor is available as an option in its own
right or in conjunction with other options, as follows:
- Option 500 "Headlight cleaning"
- Option 521 "Rain sensor"
- Option 978 "Innovation package"
- Option 970 "Business package"
Procedure: In case of customer complaint, the software status should be determined and the rain
sensor fault memory read off with either DIS or MoDiC.
Concerning fault patterns 1 to 5:
If the rain sensor is programmed with software version 1.3 or earlier, it should be replaced.
Please refer to Repair Instructions "Removing and installing / replacing rain sensor":
If the fault "2 - Adjustment to windscreen not possible" is stored in the rain sensor fault memory, the rain
sensor must be reinitialised. This process may have to be repeated two or three times.
If initialisation cannot be performed successfully, the rain sensor must be replaced.
Concerning fault patterns 6 and 7:
If a windscreen wiper double relay with a production date earlier than "379" (calendar week 37; year 1999) is
installed, this must be replaced.
Series launch of windscreen wiper double relay:
E38 - September 1998
E39 - September 1997
E46 - start of series production
If the improved parts stated above are already installed, continue troubleshooting on the basis of the fault
symptoms and the corresponding troubleshooting path in DIS or MoDiC.
Parts:
Rain sensor 61 35 6 904 012 1
Double relay 61 36 8 384 505 1

As the double relay can only fail in isolated cases, it is not necessary to clear stocks of spare parts.
61 35 90 14 00 This defect code is not contained in the official
Defect Code Catalogue but has been included in the system
Replace rain sensor:

Labour 4 FRUs
Replace double relay:
Labour 3 FRUs
Replace rain sensor and double relay:
Labour 5 FRUs E46

6 FRUs E39, E38
Replace rain sensor:

Labour 6 FRUs
Replace double relay:
Labour 4 FRUs E46

5 FRUs E38, E39
Replace rain sensor and double relay:
Labour 7 FRUs E46

8 FRUs E38, E39
Warranty type 1

Only one of the job numbers listed above may be submitted for reimbursement purposes.

12 02 00 (584)
Service interval display cannot be reset
E46 / M47, M57 / 320d, 330d
Complaint: The service interval display cannot be reset after an engine oil service or inspection.
Cause: The affected vehicles had an adapter cable installed on the instrument cluster as
instructed by Service Information bulletin 12 01 00 (534) which suppresses incorrect
actuation of battery charge warning light while the vehicle is being driven. This adapter
cable is missing the connection to pin 18.
Affected vehicles:E46 with M47/M57
Manufacturing period: September 1999 to February 2000
Remedy: Exchange of faulty wiring harness adapter.
Procedure: Replacing wiring harness adapter, please refer to Service Information bulletin
12 01 00 (534).
Note:
The pin allocation of the adapter cables in the parts stores has been corrected. The new wiring harness can be
identified by a green mark on the part designation label (see Fig. 1).
Fig. 1:
Colour marking on new adapter cable.
Parts: Adapter cable, part no. 12 51 7 786 936
Replace adapter cable:
Labour 4 FRUs
Warranty type 1

61 06 00 (633)
Sliding/tilting sunroof: no automatic functions
E38, E39, E46, E53
Situation: Every time the power is interrupted, e.g. through disconnecting battery, the sliding/tilting
sunroof initialization parameters (position identification) are reset. The automatic functions
”One-touch closing”, ”One-touch opening” and ”Convenient closing”, ”Convenient opening”
can no longer be operated.
Affected E38, E39, E46, E53 with sliding/tilting sunroof (option 401) or glass sunroof (option 403)
vehicles: Production period: from the start of series production
Action: Every time the power is interrupted, reference/initialize the sliding/tilting sunroof. The labor
time for referencing/initialization is included in the ”Disconnect battery” procedure.
Procedure:
1. Press the sliding/tilting sunroof switch to the raise position and hold in.
2. Once the raising limit position has been reached, keep the switch pressed for approx. 20
seconds.
3. Referencing/initialization is only completed if the sliding/tilting sunroof moves again briefly in the direction
of the raising limit position once the raising limit position has been reached.
For more details on procedures and warning instructions:
Refer to Repair Instructions ”Information on steel and glass sliding/tilting sunroof (function description and
initialization)”,
Repair Instructions 54 0 ....
61 04 00 (629)
Sunroof will not open or close
E38, E46
Complaints: Sliding/tilt sunroof (SHD) will not open or close.
Cause: A safety function for ensuring activation of the anti-trap function circuit in the SHD module
has triggered legitimately or reacted over-sensitively in modules with SW 3.1. Initialisation
(position detection) of the sunroof is no longer effective.
Affected vehicles:E38 with sliding/tilt sunroof (option 401) or glass sunroof (option 403)
E46 with glass sunroof (option 403)
Manufacturing period: December 1998 to August 2000
Procedure: In case of customer complaint, carry out ”reinitialisation”.
The ”reinitialisation” procedure is carried out as follows: press the SHD switch to ”raise” and
hold until the end position is reached; keep the switch pressed for a further two seconds
in this position.
The anti-trap function circuit is not active during ”reinitialisation”.
If the problem has not been rectified on completion of ”reinitialisation”, replace the sunroof drive unit together
with the module. Please refer to Repair Instructions: ”Removing and installing / replacing drive with gears for
sliding/tilt sunroof”.
E38: RA 67 61 510
E38: Sliding roof drive 67 61 6 910 472 1
mechanism with module
E46: Sliding roof drive 67 61 8 385 237 1
mechanism with module
As part of a visit to the workshop - Reinitialise sliding/tilt sunroof:
Labour 1 FRU
As part of a visit to the workshop -

Reinitialise sliding/tilt sunroof and replace drive unit:
Labour 3 FRUs
For an order without additional repair work -

Reinitialise sliding/tilt sunroof:
Labour 2 FRUs
For an order without additional repair work -

Reinitialise sliding/tilt sunroof and replace drive unit:
Labour 5 FRUs
Warranty type 1

62 02 01 (759)
ASC+T cannot be deactivated, or incorrect indicator light displays in the instrument
cluster
E46 with automatic stability control plus traction ASC+T (without DSC III,
option 210)
Complaint: On E46 vehicles from Model Year 2002 with ASC+T, the ”deactivate automatic stability
control plus traction (ASC+T) / activate automatic differential lock (ADB)” function can be
programmed. This is done by pressing the ASC button for less than three seconds. The
ASC indicator light will then remain permanently on in the instrument cluster.
If the ASC button is pressed for longer than three seconds, both the ASC+T and the ADB are deactivated. In
this case, both the ASC indicator light and the brake warning light (yellow) will light up permanently.
Complaint 1:
The ASC button is pressed for longer than 3 seconds. ASC+T and ADB are deactivated. The ASC indicator
light remains on, but not the brake warning light.
Affected vehicles: E46 (Model Year 2002) with automatic stability control plus traction ASC+T (without DSC III,
option 210)
Manufacturing period: August 2001.
Complaint 2:
The customer wishes to deactivate the ASC+T and presses the ASC button briefly (less than 3 seconds). The
ASC indicator light comes on in the instrument cluster. However, the driving dynamic control is still activated in
certain situations.
option 210)
Complaint 3:
The ASC button is pressed for longer than three seconds. Both the ASC indicator light and the brake warning
light (yellow) light up permanently. No explanation for this is given in the Owner's Handbook.
option 210)
Cause: In case of complaint 1:
Faulty encoding data in the instrument cluster.
In case of complaints 2 and 3:
The ”deactivate ASC+T / activate ADB” function introduced in Model Year 2002 is not described in the Owner's
Handbook.
The ”deactivate ASC+T / activate ADB” function will be described in the next edition of the Owner's Handbook.
The corrected Owner's Handbook is scheduled to be available from March 2002.
Procedure: In case of complaint 1:
In case of customer complaint, encode the instrument cluster using DIS CD version 27.1
or later and explain the ”deactivate ASC+T / activate ADB” function to the customer.
Proceed as follows to encode the instrument cluster with the diagnostic system:
1. Select ”Encoding”
2. Select ”Series E46”
3. Select ”Recoding”
4. Select ”10 instrument cluster”.
5. Select ”Recode control unit”.
In case of complaint 2:
In case of complaint, explain the ”deactivate ASC+T / activate ADB” function to the customer.
If the vehicle was manufactured in August 2001, also encode the instrument cluster with DIS CD version 27.1
or higher.
In case of complaint 3:
In case of complaint, explain the ”deactivate ASC+T / activate ADB” function to the customer.
Defect code subject to the current warranty terms as follows:
Within the scope of a visit to the workshop - Encode instrument cluster:
Labour 3 FRUs

Encode instrument cluster:
Labour 4 FRUs
Warranty type 1


62 01 02 (866)
Double frequency of turn indicator in instrument cluster
E46 with trailer tow hitch (option 235)
Complaint: The turn indicator in the instrument cluster flashes with double frequency, even though all
turn signal lamps are functioning correctly. The fault ”Trailer turn indicator defective” is
stored in the fault memory.
This complaint only occurs when there is no trailer connected to the vehicle.
Cause: Faulty encoding data in the central light switch (LSZ). An open circuit in the trailer current
circuit is recognised even though there is not a trailer connected to the vehicle.
Affected E46 with trailer tow hitch (option 235)
Vehicles may also be affected that were manufactured outside the manufacturing period
given, but which had a new central light switch fitted in a repair, with subsequent encoding using a DIS CD of a
version prior to 30.0.
Procedure: In case of customer complaint, the central light switch must be recoded with DIS CD
version 30.0 or later. To do this, proceed as follows in the diagnostic system:
1. Read out / clear fault memory.

2. Select ”Encoding/programming”
3. Select ”3 - Encoding ZCS/FA”
4. Select ”7 - Series E46”
5. Select ”1 - Recoding”
6. Select ”14 - LSZ”
7. Confirm ”LSZ selected. Selection correct?” with Yes.
8. Confirm ”Should LSZ be permanently allocated to vehicle?” with Yes.
9. Confirm ”Vehicle identification number correct?” with Yes.
10. Confirm ”LSZ permanently allocated to vehicle. Start encoding” with ”Yes”.
11. After encoding has been successfully completed, the message ”LSZ. The vehicle order has not been
changed. Encoding completed!” appears. Switch the ignition off. Wait 10 seconds. Switch the ignition on
again and perform a function check.
DIS CD version 30.0 is expected to be available from June 2002.
Encode central light switch:
Labour 3 FRUs

Encode central light switch:
Labour 4 FRUs
Warranty type 1

Reimbursement is limited to 36 months/100,000 km and only possible until April 2005.
62 01 01 (754)
Fuel gauge reading incorrect
E46
Complaint: The fuel gauge needle is below the top mark on scale when the vehicle's fuel tank is full.
Cause: Faulty encoding data in the instrument cluster.
Affected E46
vehicles: Manufacturing period: August 2001.
given, if a repair has been performed since August 2001 involving the exchange of the instrument cluster and
encoding with DIS CD version 27.0.
Procedure: In case of customer complaint, the instrument cluster must be recoded with DIS CD
1. Select ”Encoding”
2. Select ”Series E46”
3. Select ”Recoding”
4. Select ”10 instrument cluster”.
5. Select ”Recode control unit”.
Within the scope of a visit to the workshop - Encode instrument cluster:
Labour 3 FRUs

Encode instrument cluster:
Labour 4 FRUs
Warranty type 1


62 01 00 (527)
Odometer jumps
E46
Complaint: The odometer jumps to a lower value.
This fault can occur in the event of an undervoltage, e.g. if the battery is discharged.
Cause: Software error in the instrument cluster with a software version less than 20.0.
Manufacturing period: start of series production up to May 2000
Procedure: In case of customer complaint, the instrument cluster should be replaced.
Please refer to Repair Instructions "Removing and installing complete instrument mount",
The original value for the odometer will be taken from the light switching centre LSZ (redundant data storage)
when the instrument cluster is encoded.
Parts: Description Part number Qty.
Instrument cluster Please refer to Electronic 1
Parts Catalogue (ETK)
The stocks of the Central Parts Distribution in Dingolfing (ZTA) have been cleared.
Replace instrument cluster:
Labour 4 FRUs

Replace instrument cluster:
Labour 5 FRUs
Warranty type 1

Reimbursement is only possible until December 2002 and limited to
36 months/100,000 km
63 01 02 (807)
Headlight delayed switch-off not working correctly
E46
Complaint: The headlight's ”delayed switch-off” function is activated by operating the headlight flasher
when the vehicle is parked with the exterior lighting switched off. If the vehicle is then
locked straight away, the headlights will go out immediately.
Cause: Faulty encoding data in the lights switching centre (LSZ).
Affected E46
vehicles: Manufacturing period: September 2001 to November 2001
given, but which had a new lights switching centre fitted in a repair, with subsequent encoding using a DIS CD of
a version prior to 29.0.
Procedure: In case of customer complaint, the lights switching centre must be recoded with DIS CD
1. Select Encoding/Programming
2. Select 3 - Encoding ZCS/FA
3. Select 7 - Series E46
4. Select 1 - Recoding.
5. Select 14 - LSZ
6. Confirm ”LSZ selected. Selection correct?” with Yes.
7. Confirm ”Should LSZ be permanently allocated to vehicle?” with Yes.
8. Confirm ”Vehicle identification number correct?” with Yes.
9. Start encoding by confirming ”LSZ permanently allocated to vehicle. Start encoding” with Yes.
10. After encoding has been successfully completed, the message ”LSZ. The vehicle order has not been
changed. Encoding completed!” Switch the ignition off. Wait 10 seconds. Switch the ignition on again and
perform a function check.
DIS CD version 29.0 is available from March 2002.
- Encode lights switching centre:
Labour 2 FRUs

- Encode lights switching centre:
Labour 4 FRUs
Warranty type 1

Reimbursement is limited to 36 months/100,000 km and only possible until November 2004.
63 01 99 (401)
Headlight misting
E46
Complaint: The headlight lenses mist over.
Cause:
1. Unfavorable climatic conditions, e.g. rapidly falling temperatures at high levels of humidity
(thundery shower, car wash, underground garage).
2. Damaged seal between lens cover and headlight housing.
3. Defective seals were installed on some vehicles from the manufacturing period start of series production
to July 1999.
Affected E46
vehicles: Manufacturing period: start of series production up to July 1999
Procedure: In case of complaint, remove the lens cover. Dry the headlight and the lens with a hot air
blower.
Dry without direct contact as there is otherwise a risk of dirt contamination or fluff
formation.
Before fitting the lens cover, replace the seal (see "Parts").
Ensure that the seal is fitted exactly as described in
Headlight seal 63 12 8 380 210 1 or 2
63 12 91 50 00
During a visit to the workshop
Only on vehicles w i t h o u t headlight cleaning system
Remove and install headlight lens, left or right, dry headlight and replace seal:
Labour
5 FRUs
Remove and install both headlight lenses, dry headlights and replace both seals:
Labour 9 FRUs
Only on vehicles w i t h headlight cleaning system
Labour 7 FRUs
Labour 11 FRUs
For an order without additional repair work

Only on vehicles w i t h o u t headlight cleaning system
Labour 6 FRUs
Labour 10 FRUs
Only on vehicles w i t h headlight cleaning system

Labour 8 FRUs
Labour 13 FRUs
Warranty type 1
Only one of the job numbers listed above may be quoted for reimbursement purposes.
Reimbursement is only possible until June 2000.

63 03 00 (601)
Unauthorised replacement of xenon light components
E46
Situation: Following inspection, no fault could be found in the majority of replaced xenon light
components sent in through warranty channels.
The customer complaint and the reason for the replacement are often not known and can
also not be replicated as part of the component inspection. The diagnosis printouts that serve as an important
source of information are not provided.
Affectedvehicles:E46 with xenon lights (SA 522)Production period: from series introduction
Procedure: In the case of customer complaint, carry out diagnosis with DIS or MoDiC and work
through the corresponding test module for xenon lights.
Diagnosis procedure:
1. Carry out vehicle identification.
2. Select the "Function Selection" menu and then the subsystems "Complete Vehicle", "Body", "Lighting"
and "Low Beam Headlight" in succession in the diagnosis program.
3. Confirm the "Xenon" variant prompt with "Yes".
4. Select ”Test plan”
5. Select and carry out "Xenon Lights" test module.
6. Perform the preset measurement "Xenon Headlight Test" in the "Measuring System" subsystem.
7. If components of the xenon light system are replaced and charged through warranty, print out the
corresponding test module result (screen display of measuring system result) and send in together with
the warranty parts tag.
Defective parts will only be accepted if the exact customer complaint and the reason for replacing the
component are specified on the warranty parts tag. The diagnosis report and the test module result must
also be enclosed.
63 01 01 (688)
Xenon light intermittently inoperable
E46 with xenon light (option 522)
Complaint: The xenon light intermittently fails on either the left or right-hand side.
Cause: The wiring harness contacts the headlight's soft plastic cover and might press against the
high-voltage connector on the ignition unit. In such cases, contact problems may arise
due to the relative movement of parts.
Affected E46 with xenon light (option 522)
vehicles: Manufacturing period: from start of series production until March 2001
Procedure:
1. Remove the bulb of the xenon light in the affected headlight.

Please refer to Repair Instructions ”Replacing left-hand xenon light bulb” or ”Replacing right-hand xenon
light bulb”,
RA 63 99 076 /
RA 63 99 077.
2. Check whether there are any signs of scorching either on the base of the xenon bulb or on its high-
voltage connector.
If there are no signs of scorching on either the base of the xenon bulb or its high-voltage connector,
continue with point 4.
If there are signs of scorching on either the base of the xenon bulb or its high-voltage connector,
continue with point 3.
3. Replace both the xenon light and the ignition unit (the high-voltage connector is part of the ignition unit).
Please refer to Repair Instructions ”Replacing left-hand xenon headlight ignition unit” or ”Replacing right-
hand xenon headlight ignition unit”,
RA 63 12 870 /
RA 63 12 871.
4. Secure the wiring harnesses (bundled earth straps) behind the soft plastic covers of the left and right-
hand headlights so that they do not touch them.
Parts:
Xenon light bulb 63 12 8 361 007 1
Xenon light ignition unit 63 12 6 904 548 1
Cable tie 61 13 1 377 134 2
Defect Code Catalogue but has been included in the system, thus
Check xenon light bulb and connector and secure both wiring harnesses:
Labour 2 FRUs

Check xenon light bulb and connector, replace xenon light and ignition unit and secure
both wiring harnesses:
Labour 14 FRUs
15 FRUs (M3)
Order without additional repair operations -
Check xenon light bulb and connector and secure both wiring harnesses:
Labour 3 FRUs
4 FRUs (M3)
Order without additional repair operations -
Check xenon light bulb and connector, replace xenon light and ignition unit and secure
both wiring harnesses:
Labour 16 FRUs
17 FRUs (M3)
Warranty type 1

Reimbursement is limited to 36 months/100,000 km and only possible until March 2004.
64 06 01 (746)
Air outlet at ventilation nozzles not correct
E46 with air conditioning (option 530)
Complaint: The air outlet at the ventilation nozzles occasionally does not agree with the air
distribution setting on the air conditioning control panel (IHKR).
Cause: Software error in the IHKR control panel.
Each time the ignition is switched on or off, there is a slight movement of the motor for the
air distribution flap on the heating / air conditioning system compared with the setting on
the IHKR control panel. This fault may occur if a period of at least 16 minutes expires between the ignition being
switched on and off again (vehicle in sleep mode).
The movement is extremely small so that the fault only becomes noticeable to the customer after the ignition
has been switched on and off a number of times.
If the air distribution setting is changed at the IHKR control panel, the air distribution flap motor will always move
to the correct position. For this reason, the fault is only noticeable if the vehicle is operated for a long time with
a constant air distribution setting on the IHKR control panel.
Affected E46 with air conditioning (option 530).
vehicles: Manufacturing period: from July 2000 to August 2001
Procedure: In case of customer complaint, replace the air conditioning control panel. Please refer to
Repair Instructions ”Replacing heater controls (air conditioning regulation)”,
RA 64 11 332.
Parts:
Air conditioning control 64 11 6 911 632 1
panel
Replace air conditioning control panel:
Labour 3 FRUs

Replace air conditioning control panel:
Labour 4 FRUs
Warranty type 1

64 01 02 (846)
Automatic rear-window heater activation inactive
E46
Situation: The automatic rear-window heater function has been factory-set to ”inactive” in vehicles as
of production date April 2002.
As of DIS CD Version 30.0, this function can be activated or deactivated by means of the
Car Key Memory (CKM).
In the case of vehicles built as of production date September 2001, this function is always set to ”active” when
encoding the control panel of the heating, air-conditioning system or integrated automatic heating and air-
conditioning system using a version of DIS CD older than V30.0. It is not possible to chose between active
and inactive.
As of September 2002 (Model Year 2003), the Owner's Handbook will point out the option of selecting the
automatic rear-window heater function by means of the CKM. Until this Owner's Handbook is published, the
”active” automatic rear-window heater activation function will continue to be described. This does not correctly
describe the functional status for vehicles built as of production date April 2002.
The situation described can therefore lead to the following problems in vehicles built between April 2002 and
August 2002:
1. A customer complains that the Owner's Handbook describes the automatic rear-window heater
activation function as being set to active, but this is not the case in his vehicle.
2. The control panel of the heating, air-conditioning system or integrated automatic heating and air-
conditioning system is encoded using a DIS CD older than V30.0 and changes the automatic rear-
window heater activation function from the factory setting ”inactive” to ”active”.
Affected All E46

vehicles: Manufacturing period: from September 2001 until August 2002.
Procedure: Situation 1:
Explain to the customer the alteration made to the factory setting of the automatic rear-
window heater and that the description given in the Owner's Handbook is incorrect. Please
explain that this has nothing to do with a system error, but is a deliberate modification of the function.
Replacing a component will not alter this situation and must therefore not be performed. If the customer
would like to activate the automatic rear-window heater function, you will be able to do so by means of the
CKM once you have received DIS CD Version 30.0.
Situation 2:
If the customer does not want the automatic rear-window heater function to be active, it can be deactivated by
means of the CKM once you have received DIS CD Version 30.0.
DIS CD Version 30.0 is expected to be available in May 2002. It will also be possible to change the automatic
rear-window heater function by means of the CKM in vehicles built between September 2001 and March 2002
inclusive if a customer requests this.
Since the problems described here are not related to a product fault but to a functional modification, it is
not possible to claim for reimbursement through warranty channels.
64 02 01 (655)
Auxiliary heater starts when a door is opened
E46 / M47
Complaint: The fuel-powered auxiliary heater starts up intermittently when the vehicle is unlocked
using the radio remote control or after the driver's or front passenger door has been
opened manually. The auxiliary heater can clearly be heard running for about 2 minutes,
after which it switches off again.
Cause: Fault in fuel-powered auxiliary heater.
Affected E46 with M47 engine

vehicles: Manufacturing period: from start of series production to September 1999.
Procedure: In case of customer complaint, check whether the customer's description matches the
given fault pattern. If the fault can be verified, replace the auxiliary heater.
Proceed as follows when replacing the auxiliary heater:
1. Allow the vehicle to cool off.
2. Separate the electrical connections from the auxiliary heater.
3. Separate the coolant feed and return pipes and the fuel hose.
4. Loosen the hose clips and pull the water hoses, fresh air intake hose and the fuel hose from the auxiliary
heater.
5. Remove the front right-hand wheel housing trim.
6. Loosen the auxiliary heater exhaust pipe from the vehicle body.
7. Undo the pipe clamp for securing the exhaust pipe directly below the auxiliary heater.
8. Undo the auxiliary heater mounting bracket and remove the auxiliary heater.
9. Install a new auxiliary heater unit. To do this, use the auxiliary heater mounting bracket of the removed
auxiliary heater.
10. Refit any parts which have been removed.
11. If the auxiliary heater is activated via the K bus, encode the auxiliary heater. If the auxiliary heater is
activated by an analogue signal, the auxiliary heater cannot be encoded.
From start of series production until August 1998: analogue activation of auxiliary heater
Since September 1998: activation of auxiliary heater via K bus
12. Top up coolant. Please refer to Repair Instructions ”Draining and adding coolant on M47” - Repair
Instructions 1700005.

Auxiliary heater 64 12 6 915 831 1
Within the course of a visit to the workshop - Replace auxiliary heater:
Labour 21 FRUs

Replace auxiliary heater:
Labour 23 FRUs
Warranty type 1

36 months / 100,000 km.
64 06 00 (608)
Auxiliary heater: Exhaust odour in vehicle interior
E46 / M47
Complaint: Exhaust fumes can sometimes be smelled in the vehicle interior when the engine is
running. This is particularly noticeable when the vehicle is stationary or moving very
slowly.
Cause: Small quantities of exhaust fumes from the auxiliary heater can get into the vehicle interior
through the vehicle's ventilation system. Due to the very low concentrations involved, this
does not constitute a health hazard.
Affected vehicles:E46 with M47 engine
Manufacturing period: start of series production to September 1999.
Remedy: In case of customer complaint, extend the exhaust pipe of the auxiliary heater.
Procedure: Proceed as follows to extend the exhaust pipe:
1. Unfasten the underbody trim panel in the area of the exhaust gas outlet and fold the trim panel down.
2. Unfasten and remove the pipe clamp and exhaust pipe.
3. Screw the flexible exhaust pipe onto the exhaust silencer using the pipe clamp previously removed.
4. Press the retaining clip on the anchorage for the flexible exhaust pipe into the longitudinal engine carrier.
Screw on the flexible exhaust pipe with the hose clamp (1) and the screw (2). The heat protection hose
(3) is already prefitted and secured with cable tie (4)
(see Fig. 1).
Figure 1
1= Hose clamp
2= Screw
3= Heat protection hose
4= Cable tie
5. Remove the screw on the anchorage (1) of the heat shield. Screw the flexible exhaust pipe and the hose
clamp together onto the heat shield with the screw removed previously. The heat protection hose (2) is
already prefitted and secured with cable tie (5). Screw the flexible exhaust pipe to the vacant hole by the
two retainers (4), each with a hose clamp (3) (see Fig. 2).
Figure 2
1= Anchorage
2= Heat protection hose
3= Hose clamp
4= Bracket
5= Cable tie
6. Bend the end of the flexible exhaust pipe slightly down.
7. Make a hole, ∅ 5 mm (for condensed water drain), at the lowest point of the flexible exhaust pipe.
9. Refit the underbody trim panel.
Parts:
Exhaust pipe extension 64 12 6 913 912 1
retrofit kit
During a visit to the workshop
Extend auxiliary heater exhaust pipe:
Labour 4 FRUs

Extend auxiliary heater exhaust pipe:
Labour 6 FRUs
Warranty type 1

Reimbursement is only possible until December 2002 and limited to 36 months/100,000 km.
00642801/1299
Correct fuse assignment for additional water pump
E46 / M47 und M57
Situation: In the above-mentioned vehicles, there may be implausible fault entries after switching off
the ignition in the Digital Diesel Electronics (DDE), in the light switch cluster (LSZ), in the
instrument cluster and in the Dynamic Stability Control (DSC). The cause is incorrect wiring
of the line for the voltage supply of the additional water pump in the fuse carrier.
Affected vehicles:E46 with M47 engine with air conditioning (optional equipment 530) or with automatic air
conditioning (optional equipment 534) or with air-conditioning preparation (optional
equipment 857) or with M57 engine; production period: According to vehicle
identification number selection (September 1999 to November 1999).
Measure: Modify fuse assignment for the additional water pump.
Procedure:
1. Disconnect battery negative lead.
2. Remove glove box.
3. Undo the three lower bolts on the fuse carrier.
4. Detach the fuse carrier.
Do not break off the side bracket when detaching.
5. Undo the cable ties and disassemble the fuse carrier.
6. Unpin the green-red line at fuse slot 23.
7. Unpin the red-grey line at fuse slot 62, cut off the contact, strip the insulation and crimp the double flat
spring contact with a double outlet.
8. Connect the green-red line from fuse slot 23 to the double outlet of the double flat spring contact in fuse
slot 62.
9. Discontinuation of fuse 23 (7.5A).
10. Reassemble the vehicle.
11. Clear diagnostic fault entries from fault memory.
Parts: Designation Part number Quantity

Double flat spring contact 61 13 8 364 526 1
with a double outlet
Cable strap 61 13 1 367 599 3
00 64 28 01 00
Correct fuse assignment
Flat rate units 11 FRUs
Warranty type 1
Warranty level 1
64 01 03 (944)
Excessive heating at temperatures below 0° C
E46
Complaint: At outside temperatures of less than 0° C, the vehicle is heated too strongly. The interior
temperature felt is much higher than that set.
Moreover, at these ambient temperatures, the blower speed is implausibly boosted in the
automatic air-conditioning program.
Cause: Software error in the instrument cluster (versions 31.0 and 32.0).
Affected vehicles:E46 with air-conditioning system or integrated automatic heating and air-conditioning
(options 530 or 534)
Manufacturing period: April 2002 to December 2002
Procedure: Only recode the air-conditioner control unit in cases of customer complaint.
DIS CD ”1st update to CD 32.0” or a later version is required.
Recoding the air-conditioner control unit will eliminate the software error in the instrument
cluster.
Note:
Recoding will not correct the faulty temperature status in the IHKR/IHKA.
Parts: Do not replace any parts - this is not necessary.
Within the framework of a visit to the workshop:
Recode air-conditioner control unit.
Labour 2 FRUs
In case of order without additional repair work:

Recode air-conditioner control unit.
Labour 4 FRUs
Warranty type 1

64 03 00 (563)
Failure or continuous operation of electric fan
E46
Complaint: 1. The electric fan (suction fan or pressure fan) fails.
2. The electric fan (suction fan or pressure fan) runs on for longer than the maximum
permissible run-on time of 12 minutes when the engine is switched off.
Cause: Faulty clock regulator in the electric fan.
Affected E46
vehicles: Manufacturing period: start of series production to April 1999.
Procedure: In case of customer complaint, perform diagnosis with DIS or MoDiC. When doing this,
work through the individual test modules.
If the electric fan is faulty, replace it.
Parts:
Shroud with fan (suction fan) See Electronic 1
Pressure fan See Electronic 1
Read off and clear DME/DDE fault memory and replace electric fan:
Job number 00 52 772 Shroud with fan (suction fan)
Labour 4 FRUs - M43 and M52

7 FRUs - M47
Read off and clear DME/DDE fault memory and replace electric fan:
Job number 00 52 773 Pressure fan
Labour 7 FRUs
In case of order without additional repair operations - Read off and clear DME/DDE fault
memory and replace electric fan:
Job number 00 52 171 Shroud with fan (suction fan)
Labour 6 FRUs - M43 and M52

8 FRUs - M47
In case of order without additional repair operations - Read off and clear DME/DDE fault
memory and replace electric fan:
Job number 00 52 172 Pressure fan
Labour 9 FRUs
Warranty type 1

Only one of the above job numbers may be quoted for reimbursement purposes.
36 months / 100,000 km.
64 01 99 (414)
Heater blower fails or runs permanently
E39, E46, E53 with air conditioning (option 530) or automatic air conditioning
(option 534)
Complaint: The heater blower of the air conditioning system (IHKR) or of the automatic air conditioning
system (IHKA) intermittently or permanently fails, or continues to run at a constant speed
despite the blower speed being changed manually. The control panel of the automatic air
conditioning system (IHKA) shows the set blower speed to be unchanged.
This fault pattern is fundamentally different from the complaint ”air output decreases after prolonged operation
of the automatic air conditioning”. E46: please refer to Service Information bulletin
”No air output in air conditioning mode”,
SI 64 04 00 (572)
Cause: Faulty blower output stage.
The IHKR/IHKA control panel is not faulty. In this case, replacing the control panel is
not justified and cannot be reimbursed through warranty.
Affected E39, E46, E53 with air conditioning system (option 530) or automatic air conditioning
vehicles: system (option 534)
Manufacturing period: start of series production until June 2001.
Procedure: In case of customer complaint, replace the blower output stage.
E39: please refer to repair instructions ”Replacing limit switch for fan of heater/air
conditioner”, 64 11 222
E46: please refer to repair instructions ”Replacing limit switch for fan of heater/air conditioner”,
64 11 228
E53: please refer to repair instructions ”Replacing limit switch for fan of heater/air conditioner”,
64 11 228 (IHKA)
64 11 227 (IHKR)

Blower output stage as per Electronic Parts 1
Catalogue (EPC)
Replace blower output stage:
Labour 1 FRU E39

7 FRUs E46
7 FRUs E53 (IHKR)
Labour 3 FRUs E53 (IHKA)

Replace blower output stage:
Labour 3 FRUs E39

9 FRUs E46
8 FRUs E53 (IHKR)
Labour 5 FRUs E53 (IHKA)
Warranty type 1


64 03 03 (958)
Humming, droning noises when air-conditioning system is switched on
E46 M47/TU, M52, M54, M56, M57, N40, N42
Complaint:
1. E46 with M47/TU:

Humming or droning noises in the engine speed range 2500 - 3200 rpm with a peak at 2900 rpm when
driving steadily or under load.
2. E46 with M52, M54, M56:
Humming or droning noises in the engine speed range 2000 - 4000 rpm. In addition - or at very low engine
speeds - howling noises (similar to timing chain) may also occur.
3. E46 with M57:
Humming or droning noises in the engine speed range 2000 - 3500 rpm when driving steadily or under
load.
4. E46 with N40, N42:
Humming or droning noises at all engine speeds.
Cause: The vibrations of the engine are transmitted into the vehicle interior through the intake
pipe of the air-conditioning compressor.
Affected vehicles:E46 with air-conditioning system (option 530) or automatic air-conditioning system
(option 534) and the following engine versions:
1. E46 with M47/TU (only 320d)

Manufacturing period: September 2001 until 9 April 2002
2. E46 with M52, M54
Manufacturing period: start of series production until January 2001
3. E46 with M54, M56
Manufacturing period: January 2001 until 25 September 2002
4. E46 with M57
Manufacturing period: September 2001 until 14 April 2002
5. E46 with N40, N42
Manufacturing period: from March 2001
Procedure: In case of customer complaint, replace the ”intake pipe from evaporator to air-conditioner
compressor”. New intake pipes are fitted with a vibration damper weight. On vehicles with
M54, M56, N40 and N42 engines, a ”muffler”, a small expansion tank, is fitted on the
compressor side of the intake pipe.
1. Drain air-conditioning system.
2. Replace the intake pipe from the evaporator to the air-conditioner compressor.
3. Evacuate the air-conditioning system and refill.
Comply with instructions for replacing drier bottle 64 53
Important!
In such cases, exchanging the air-conditioner compressor or expansion valve will not remedy the
situation.
Parts:
M47/TU intake pipe 64 53 6 923 958 1
M52, M54 intake pipe 64 53 6 933 368 1
(until January 2001)
M54, M56 intake pipe 64 53 6 923 956 1
(from January 2001)
M57 intake pipe 64 53 6 923 957 1
N40, N42 intake pipe 64 53 6 930 364 1
Material and labour costs incurred can be claimed through the usual warranty channels subject to current
Reimbursement: Defect code warranty terms.
Replace air-conditioning intake pipe.
Labour M47/TU - 18 FRUs

M57 - 19 FRUs
M52/M54/M56 - 18 FRUs
N40/N42 - 19 FRUs
Replace air-conditioning intake pipe.
Labour M47/TU - 19 FRUs

M57 - 21 FRUs
M52/M54/M56 - 20 FRUs
N40/N42 - 21 FRUs
Warranty type 1


64 02 00 (553)
IHKA control panel: LED in A/C button flashes
All models with integrated automatic heating and air conditioning (optionÂ 534)
Complaints: After a new IHKA control panel has been installed, the LED in the A/C button flashes.
Cause: The flashing of the LED in the A/C button indicates that the automatic air-conditioning
system is in the compressor protection mode. This protective function is intended to
ensure an adequate refrigerant distribution the first time the air conditioner is operated (in
the vehicle factory), before the engine is revved up.
The spare part is identical to the IHKA control panel used in series production. For this reason, the said
protection mode is always active the first time a new IHKA control panel is installed. The LED in the A/C button
will then flash continually until the A/C compressor has been engaged for about 90 seconds at an engine
speed of less than 1500 rpm.
Affected vehicles:All models with integrated automatic heating and air conditioning (option 534)
Procedure: After a new IHKA control panel has been installed, the air conditioner must be run
continually with the engine at idling speed until the LED in the A/C button stops flashing.
Under certain marginal conditions (e.g. very low ambient temperatures), it is possible that
the A/C compressor is not permanently active. In such cases, the LED in the A/C button can continue flashing
for several minutes.
64 08 00 (645)
Musty odour from heating and air conditioning system, evaporator cleaning
All model series
Complaint: When operating the heating and air conditioning system, a musty odour briefly occurs in
the vehicle. This occurs mostly immediately after starting the engine with the air
conditioning switched on or after switching off the air conditioning while driving.
Cause: The cause for the customer complaint is not a fault in the air conditioning of the vehicle.
The formation of odour is due to environmental factor during the operating period of the
heating and air conditioning system.
The constant condensation of air humidity at the evaporator over a long operating period of the heating and air
conditioning system creates a favourable environment for bacteria and other micro-organisms.
Together with dirt contamination brought in by the fresh air, this may cause microbiological growth on the
evaporator and consequently a musty odour.
Regularly changing the microfilter may reduce the entry of dirt contamination and therefore delay or prevent
the development of aforementioned customer complaint.
Replacement of the evaporator has no continuous effect as microbiological organisms may redevelop.
Invoicing as warranty is not justifiable as there is no technical fault.
Vehicles concerned:All series with air conditioning (IHKR) or automatic air conditioning (IHKA).
Procedure: 1. Evaporator cleaning with spray lance

The most efficient and lasting method of eliminating the musty odour from the air
conditioning is to clean the evaporator with the aid of a spray lance. With this procedure,
the disinfectant is sprayed with high pressure directly on the evaporator.
Description of the operations:
For the detailed description of the procedure for the following series, please see the respective repair
instructions:
E39/E53 with air conditioning (IHKR): Cleaning evaporator
E39/E53 with automatic air conditioning (IHKA): clean evaporator (automatic air conditioning)
E46 with air conditioning (IHKR): Cleaning evaporator
E46 with automatic air conditioning (IHKA): clean evaporator (automatic air conditioning)
E65/E66: Cleaning evaporator
E60/E61/E63/E64: Cleaning evaporator
E85/E86: Cleaning evaporator
E81/E82/E87/E88/E90/E91/E92/E93: Cleaning evaporator
E70/E71/E72: Cleaning evaporator
F01/F02/F03/F04/F06/F07/F10/F11/F12/F13/F18: Cleaning evaporator
F20/F21/F22/F23/F30/F31/F32/F33/F34/F35/F36/F80/F82/F83/F87: Cleaning evaporator
I01t: Cleaning evaporator
F45/F46/F48/F49: Cleaning evaporator
F54/F55/F56/F57/F60: Cleaning evaporator
G05/G06/G07/G11/G12/G14/G15/G16/G30/G31/G32/G38/F90/F91/F92/F93/F95/F96: Cleaning evaporator
G01/G02/G08/G29: Cleaning evaporator
2. Cleaning with the evaporator cleaning device "Aircomatic"

As an alternative, the evaporator can be cleaned using the "Aircomatic" cleaning system made by WYNN’S.
For this purpose, use the "Airco-Clean" cleaning agent made by the same company.
WYNN’S describes this procedure as "Ultrasound procedure".
The cleaning power using the "ultrasound procedure" is lower as compared to cleaning with a spray lance.
If the "ultrasound procedure" does not bring long-term success due to very severe dirt contamination of the
evaporator, clean the evaporator using a spray lance and the heating and air conditioning system cleaning
agent.
Note:
This procedure is to be used for vehicles for which no spray lance is offered.
Description of the operations:

Remove microfilter (replace with new filter after cleaning)
Start the vehicle
Switch on air conditioning
Set temperature control to lowest value
For automatic air conditioning (IHKA): Switch off automatic air distribution/supply
Select the lowest fan speed
Set ventilation to upper body area
Adjust air supply to air recirculation function
Shake the "Airco-Clean" bottle well
Place the ultrasound device upside down
Screw in the "Airco-Clean" bottle with its opening facing upwards into the device
Return ultrasound device to initial position allowing the contents of the bottle to partially flow into the
device
Place the ultrasound device in the footwell on the passenger's side
Connect the atomisation hose to the device
Place the atomisation hose so that the recirculated air system can take in the emitted vapour well
Do not kink the hose!
Connect the ultrasound device using the included cable
Atomisation starts!
Close vehicle doors and side windows
Attention:
No one must remain in the vehicle during treatment!
Treatment is complete after approx. 20 minutes and the ultrasound device stops
After treatment, open doors and air the vehicle for approx. 5 minutes
After treatment pour out the residual liquid in the ultrasound device
Briefly rinse the ultrasound device with water
Parts required: 1. Cleaning with spray lance
Spray lance Order/part number Quantity

-E39/E46/E53/E83 64 1 450 1
- E65/E66/E67 (left-hand drive vehicle) 64 1 280 1
- E65/E66/E67 (right-hand drive vehicle) 64 1 290 1
-E60/E61/E63/E64 64 1 480 1
- E85/E86 (left-hand drive vehicle) 64 1 490 1
- E85/E86 (right-hand drive vehicle) 64 1 250 1
- E81/E82/E87/E88/E90/E91/E92/E93 (left-hand drive vehicle) 64 1 260 1
- E81/E82/E87/E88/E90/E91/E92/E93 (right-hand drive vehicle) 64 1 270 1
- E70/E71/E72 (left- and right-hand drive vehicle) 64 1 300 1
- F01/F02/F03/F04/F06/F07/F10/F11/F12/F13/F18 (left-hand drive vehicle) 83 30 2 222 502 1
G01/G02/G08/G29 (left-hand drive vehicle)
- F01/F02/F03/F04/F06/F07/F10/F11/F12/F13/F18 (right-hand drive vehicle) 83 30 2 364 733 1

G01/G02/G08/G29 (right-hand drive vehicle)
-F20/F21/F22/F23/F30/F31/F32/F33/F34/F35/F36/F80/F82/F83/F87 83 30 2 344 001 1

(left hand drive vehicle)
-F20/F21/F22/F23/F30/F31/F32/F33/F34/F35/F36/F80/F82/F83/F87 (right- 83 30 2 289 613 1

hand drive vehicle)
-I01 83 30 2 413 653 1
-F45/F46/F48/F49 83 30 2 413 653 1
-F54/F55/F56/F57/F60 83 30 2 413 653 1
-G05/G06/G07/G11/G12/G30/G31/G32/G38/F90 (left-hand drive vehicle) 83 30 2 411 757 1
-G05/G06/G07/G11/G12/G30/G31/G32/G38/F90 (right-hand drive vehicle) 83 30 2 414 999 1
Spray gun
SATA spray pistol 81 45 9 429 217 1
Heating and air conditioning system cleaning agent
Heating and air conditioning system cleaning agent (only for cleaning with 83 19 2 180 507 1
spray lance!)
Heating and air conditioning system cleaning agent is used undiluted. No rinsing required.
The spray lance spray gun can be obtained from the special tools online catalogue; the heating and air
conditioning system cleaning agent can be obtained directly from BMW Group Parts.
2. Cleaning with the evaporator cleaning device "Aircomatic"

(Valid for all series)

Heating and air conditioning system cleaning agent 83 19 2 409 611 1
Heating and air conditioning system cleaning agent is used undiluted.
The "Aircomatic" cleaning device and the "Airco-Clean" cleaning agent can be obtained directly from
BMW Group Parts.
64 04 00 (572)
No air throughput in air conditioning mode
E46 with automatic air conditioning system (option 534)
Complaint: After the automatic air conditioning system (IHKA) has been in operation for some time,
the airflow out of the ventilation outlets continuously decreases. In isolated cases, there
is absolutely no air throughput. The setting of the airflow control (blower switch) in the
IHKA control panel remains unchanged. The automatic air conditioning system blower can still be heard to be
running.
When the automatic air conditioning system, or the engine, has been switched off, a significant puddle of
condensation forms under the vehicle. When the automatic air conditioning system is switched back on again
(after at least 30 minutes immobilisation period), the air throughput from the ventilation outlets is again correct.
Cause: A faulty evaporator temperature sensor causes the automatic air conditioning system
evaporator to ice over in air conditioning mode.
This adversely affects, and can even cut off, the airflow into the vehicle interior.
Affected E46 with automatic air conditioning (option 534)
vehicles: Manufacturing period: start of series production until February 2001
Procedure: In case of customer complaint, perform a function check of the evaporator temperature
sensor and replace it if necessary.
1. With the engine switched off and at room temperature (approx. 20 °C), read off the temperature value of
the evaporator temperature sensor using the DIS / MoDiC.
2. Then start the engine and switch on the automatic air conditioning system (press the air conditioning
button on the IHKA control panel). Set the specified temperature to 16 °C and the blower to the lowest
speed.
After a running time of approx. 3 to 4 minutes, the temperature of the evaporator temperature sensor
displayed in the DIS / MoDiC must then drop to a value less than 10 °C.
3. If such a change in the temperature value does not occur when the described function check is
performed, the evaporator temperature sensor must be replaced.

Heater element/evaporator 64 11 8 380 673 1
temperature sensor
Check the evaporator temperature sensor:
Labour 2 FRUs

Check and replace the evaporator temperature sensor:
Labour 5 FRUs

Check the evaporator temperature sensor:
Labour 4 FRUs
In case of order without additional repair operations, check and replace the evaporator
temperature sensor:
Labour 6 FRUs
Warranty type 1

Reimbursement is limited to 36 months / 100,000 km and only possible until February 2004.
00642701/1299
Replace heating cut-off relay and correct fuse assignment or auxiliary water pump
E46 / M47
Situation: For the aforementioned vehicles, there may be implausible fault entries after switching off
the ignition in the Digital Diesel Electronics (DDE), in the light switch cluster (LSZ), in the
instrument cluster and in the Dynamic Stability Control (DSC). The cause is incorrect wiring
of the voltage supply line for the auxiliary water pump.
In certain situations, the engine cannot be stopped.
Affectedvehicles:E46 with M47 engine and no air conditioning (SA 530) or automatic air conditioning (SA
534)Production period: Corresponding to vehicle identification number selection
(September 1999 to October 1999).
Measure: Modify fuse assignment for the additional water pump.
Replace the heating cut-off relay.
Procedure: 1. Disconnect battery negative lead.
2. Remove glove box.
3. Undo the lower three screws from the fuse carrier.
4. Detach the fuse carrier.
Do not break off the side bracket when detaching.
5. Undo the cable ties and disassemble the fuse carrier.
6. Unpin the green-red line at fuse slot 23.
7. The retaining lugs on the contact must not be damaged;crimp on new double flat spring contact if
necessary.
8. Plug the green-red line into fuse holder 62.
9. Insert fuse 23 (7.5 A) into fuse location 62.
10. Remove support from front storage compartment, see repair instructions 51 16....
11. Replace existing heating cut-off relay with a new relay.
13. Delete the fault memory.

Double flat spring contact 61 13 8 377 730 1
Black two-pole make 61 36 1 388 364 1
contact relay
Cable strap 61 13 1 367 599 3
00 64 27 01 00
Replace heating cut-off relay and correct fuse assignment:
Flat rate unit 14 FRUs
Warranty type 1
Warranty level 1
61 01 03 (952)
Airbag: Repair Instructions for belt tensioner and/or side airbag triggering circuit
E46, R50/R53, E53, E38, E39, E36, Z3, Z4
Complaint: The airbag warning lamp is permanently lit.
Fault codes indicating a fault in the triggering circuit of the driver/passenger-side belt
tensioner and/or side airbag (R50/R53 only) are stored in the fault memory of the airbag
control unit.
Cause: The following principal causes of failure are currently known:
Increased contact resistance at the contacts of the seat connectors due to deposits.
Faulty crimping at the contacts of the seat connectors.
Analysis of damaged parts has shown that the pyrotechnic belt tensioner and/or side airbag itself is rarely the
cause.
Affected vehicles:E46, R50/R53, E53, E38, E39, E36, Z3, Z4
Procedure: In case of customer complaint, replace the two wires to the relevant belt tensioner and/or
side airbag with a repair wiring harness as follows:
Repair Instructions for E46 (Enclosure 1)
Repair Instructions for R50/R53 (Enclosure 2)
Repair Instructions for E38, E39 (Enclosure 4)
Repair Instructions for Z3 (Enclosure 6)
Important:
The minimum contact resistance must be achieved when a repair harness is fitted. For this
reason it is essential that the hotspots in the Repair Instructions are observed.
Service Information bulletin SI 61 01 99 (397) ”Airbag, Repair Instructions for triggering circuits”
remains valid for damaged or defective wires and connectors in the triggering circuits of the airbag
system.

Parts:
Repair wiring harness Please refer to Enclosures Please refer to Enclosures
Job number Please refer to Enclosures
Labour Please refer to Enclosures
Warranty type 1

Reimbursement is limited and only possible for a restricted time, please refer to Enclosures.
00653901/1299
Check side airbag impact sensors and recode the airbag control unit
E46 CKD Mexico without discontinuation of side airbag (optional equipment
259)
Situation: In certain driving situations, the side airbag may be activated unnecessarily, i.e. without
the occurrence of an accident.
Vibration pulses that may occur, for example, by driving hard against kerbstones or by
driving quickly through large potholes, are transferred via the front wheel suspension and the body to the
impact sensors of the side airbags and/or into the airbag control unit. Depending on the type of load, these
pulses could be detected by the airbag control unit in individual cases as a signal for triggering the airbag.
Affected vehicles:E46 CKD Mexico without discontinuation of side airbag (optional equipment 259 )
Production period: According to vehicle identification number selection (series
introduction to April 1999).
Measure: Check both side airbag impact sensors, replace if necessary and recode the airbag
control unit.
Procedure: Check the impact sensor and replace, if necessary:
1. Remove both front seats See repair instructions 52 13 000.
2. Fold back the carpet in the area of the front seats and uncover both side airbag impact sensors.
3. Read off the part number from the label of both side airbag impact sensors.
4. If the part number 65 77 6 902 054 appears on the label: The impact sensor is OK and need not be
replaced. Continue with Point 7. If the part number 65 77 6 902 054 does not appear on the label: The
impact sensor must be replaced. Continue with Point 5.
5. Turn the ignition key to “zero” position.
6. Replace both side airbag impact sensors. See repair instructions 65 77 550.
7. Assemble vehicle. In each case, the 2 hexagon screws and 2 hexagon nuts on the seat mounting must
be replaced.
8. If necessary, delete any stored fault codes.
Recode the airbag control unit:
1. Load DIS or MoDiC III with CD-ROM version 20.0 (in language versions Spanish or US English only) or
higher.
2. Connect DIS or MoDiC III to the diagnostic socket.
3. Switch the ignition on.
4. Select encoding ZCS (“3”).
5. Select series E46 (“7”).
6. Select recoding (“1”).
7. Select airbag (“19”).
8. For further procedure, follow operator prompting.
Following a successful check and, if necessary, the replacement of the impact sensors and successful
recoding, the vehicle must be identified with a white colour spot on the right spring strut dome next to the
vehicle identification number (see figure). Apply the identification to the paint, not to the transparent film.
N.B.:
1. In rare, individual cases, the DIS and/or MoDiC III may not be able to read the vehicle identification
number out of the instrument cluster. In this case, the systems will display the fault message “Coding
data incomplete or faulty. CoapiReadFgNr Error Code: 2062”. In such cases, a software reset in the
instrument cluster (Test 21) or a battery reset must be carried out:
Software reset
With “Terminal R” switched on, operate the left combination button for 5 seconds (test mode), and the
individual test functions can then be called up by repeatedly tapping the button briefly. To unlock the test
functions (3 to 21), select test function 19. After approx. 2 seconds, the alternating display “L on” and “L
oFF” appears in the submenu 19.0. In “L oFF”, operate the left combination button (unlock test functions).
Then tap through the test functions again up to test 21, and the display “rESEt” appears.
After turning the ignition key to “zero” position, the test functions are locked again.
Battery reset
Disconnect the battery with the ignition switched off, bring the two cable ends together briefly and
connect the battery again.
Then switch on the ignition again and delete any possibly stored fault codes. The encoding can then be
carried out.
2. Before encoding, any possibly stored fault codes in the airbag control unit must be read out, the fault
cause must be rectified and the fault codes must be deleted. If this does not happen, DIS/MoDiC will
display the fault message “Encoding cannot be carried out successfully. Carry out troubleshooting with
diagnosis.”

Side airbag impact sensor 65 77 6 902 054 2
M10 hexagon screw 52 10 8 211 438 4
M10 hexagon nut 61 61 8 215 610 4
00 65 39 01 00
Check both side airbag impact sensors and recode the airbag control unit:
Check and replace both side airbag impact sensors and recode the airbag control unit:
Warranty type 1
Warranty level 1
Only one of the job numbers specified above may be used for billing.
65 13 00 (641)
Deactivating and reactivating airbags/acoustic seat belt reminder
All Series from model year 1994
Situation: If expressly desired by the customer and at the customer's responsibility, the following
airbags can be deactivated and reactivated depending on the vehicle type:
Driver's and front passenger airbag
Front left and/or front right side airbags
Rear left and/or rear right side airbags
Front left and/or front right head airbags
Rear left and/or rear right head airbags
Important note when travelling with children:
Children younger than 12 years of age or smaller than 150 cm may only travel if they are secured in suitable
child restraint systems. Child restraint systems may only be used on the front passenger seat when the
airbag is deactivated, as otherwise there is a substantial risk of injury to the children if the airbag is deployed,
even if they are seated in a child restraint system. If it cannot be prevented that children lean out of their seat
in the direction of the door trim panel, the side airbag in the rear should be deactivated. Otherwise, there is a
risk of considerable injury if the side airbag deploys.
Vehicles concerned:The following exceptions relating to the deactivation or reactivation of the airbag
must be observed.
E64 Production period: from series introduction until August 2005)
The different seat/seat belt system (SGS) means that the legal standard ECE‐R21 ”new” cannot be met.
For technical reasons, the E64 cannot be approved in accordance with ECE‐R21 ”old”, as in the case of
the E46 Convertible. For this reason, it is not permissible to deactivate the front passenger airbag by
means of conversion (encoding).
E83 Production period: from September 2004
A modification to the front passenger airbag cover means that the front passenger airbag is no longer to
be deactivated by conversion (encoding). For these vehicles, a key switch is available optionally and as
a retrofit kit.
R50/52/53 Vehicles with "JOHN COOPER WORKS sports seats":
The decisive document for installation is the installation instructions for "Retrofitting John Cooper Works
sports seats" The vehicle's operating licence is not invalidated if "John Cooper Works sports seats" are
retrofitted. The "JOHN COOPER WORKS sport seat" is an element of the European operating licence of
the MINI (R50/R53). Approval of the installation by a technical control organization and entry into the
vehicle documents is not required.
Thus, the following documentation in the appendices of the service information is not required when
installing the "JOHN COOPER WORKS sport seats":
Procedure for deactivation or reactivation of the airbags in the dealer organisation; Section
"Documentation of the conversion" (Appendix 1)
Documentation of the customer agreement and the performed work (Appendix 3)
All BMW F-series, BMW i and MINI from R58:
In these vehicles, deactivation/activation of the airbags is only possible using a factory-installed key
switch.
The key switch cannot be retrofitted!
It is not possible to deactivate/activate the airbags by means of conversion.
Procedure: Deactivating / reactivating airbags

Attention!
For vehicles with belt force limiter without key switch, the seat belt must be exchanged for a "seat
belt without belt force limiter" when the front passenger airbag is deactivated.
It is not necessary to replace the seat belt in the E46/C.
If the front passenger airbag is reactivated, the seat belt must again be replaced with a "seat belt
with belt force limiter" when the front passenger airbag is reactivated.
In Australia and Korea it is not permitted to deactivate the front passenger airbag.
For vehicles for which a key switch is available for deactivating/reactivating the airbags is optionally available,
retrofit kits are also available for retrofitting a key switch (exception: all BMW F-series, BMW i, MINI from R58)
Tables 1 and 2 provide an overview of the measures needed for deactivating/reactivating the airbags and the
acoustic seat belt warning, taking the stipulations for the specific models into account.
Attention!
The combination of certain equipment specifications, national-market versions and country-
specific regulations may result in deviations to the data presented in Tables 1 and 2. If in
doubt, contact Technical Support before carrying out any work.
Key:
1 - Deactivation occurs through a conversion with the diagnosis system.
2 - Deactivation takes place via a factory-installed or retrofitted key switch.
3 - Deactivation takes place via a factory-installed key switch, which cannot be retrofitted.
Table 1: Airbag deactivation/reactivation
Model series Date of Front airbag Side airbag Head airbag Remarks
introduction
Driver Passenger Front Rear Front Rear
E34 From 09.93 1 1 1 Please refer to
Enclosure 5.
Enclosure 6.
E36/Z3 from series 1 1 1
production
E38 from series 1 1 1 1 1 1
production
production
E46 from series 1 1 1 1 1
production
E52 from series 1 1 1
production
production
E60/E61 up to 08.05 1 1 1
E60/E61 From 09.05 2 2 1
E63 up to 08.05 1 1 1
E63 From 09.05 2 2 1
E64 up to 08.05 1 1
E64 From 09.05 2 2 1
E65/E66 from series 1 1 1
production
E70/71/72 from series 2 2
production
production
E83 up to 08.04 1 1 1
E83 From 09.04 2 2 1
E84 from series 2 2
production
E85/86 from series 2 2
production
E87 From 03.05 2 2
E89 from series 2 2
production
E90/91/92/93 from series 2 2
production
R50/R53 up to 06.04 1 1 1
R50/53 From 07.04 2 2 1
R52 from series 2 2
production
R55/56/57 from series 2 2
production
MINI from R58 from series 3 3
production
BMW F-Series from series 3 3
production
BMW i from series 3 3
production
Deactivation/reactivation of acoustic seat belt warning

Deactivate and reactivate the acoustic seat belt warning for the driver and front passenger by conversion as
per the table below.
Note:
Deactivating the acoustic seat belt warning is not permitted in Japan.
With the E53, the deactivation / reactivation of the acoustic seat belt warning on the front
passenger side is only possible with the installation of a Light Check Module (LCM) / light module
(LM) with a coding index 24 or higher (series from April 2005).
Deactivating the acoustic seat belt warning in R50/52/53 is not possible.
Table 2: Deactivating/reactivating the acoustic seat belt warning
Model series Driver and front passenger Front passenger only Remarks
E53 1
E70/71/72 1 only in conjunction
with option 230
E60/61/63/64 1
E65/66 1
E81/82/87/88 1
E83 1
E84 1
E85/86 1
E89 1
E90/91/92/93 1
MINI from R55 1
BMW F-Series 1
BMW i 1
Location of documents for deactivating or reactivating the airbag
- Procedure for deactivating and reactivating airbags in the Please refer to Enclosure
dealer organisation: 1.
- For how to encode the airbag control unit: Please refer to Enclosure
2.
- For notes on documenting the customer's consent and Please refer to Enclosure
the work carried out: 3.
- Identification of airbag systems Please refer to Enclosure
4.
- Deactivating or reactivating the airbags in E34 series Please refer to Enclosure
vehicles 5.
vehicles (excluding Z3) 6.
- Deactivating or reactivating the acoustic seat belt Please refer to Enclosure
warning 7
Note:
Only the airbags listed in the table can be
deactivated.
- Deactivating or reactivating the airbags in series See repair instructions
E36/Z3,38,39,46,52,53,60,61,63,65,66,83 (to August RAGRP72-7212DEAKTIV-
2004), R50,53 (to July 2004) OHNE
- Deactivating or reactivating the front passenger airbag See repair instructions
using a key switch in series E60,61,63,64 (from RAGRP72-7212DEAKTIV-
September 2005) E83 (from September 2004), E87 (from WITH
March 2005) E85,70,90,91,92,93,R50,53 (from July 2004),
R52

Upper front seat belt without belt force See Electronic Parts Catalogue 1
limiter (EPC)
Sets of forms/parts, multilingual (with 01 39 0 028 759 1
warning stickers)
00654001/1299
Recode airbag control unit
E46 CKD Mexico
Situation: In certain driving situations, the side airbag may be triggered erroneously, i.e. not caused
by an accident.
Vibration pulses from situations such as colliding strongly with the kerb or driving quickly
over large potholes are transferred through the front wheel suspension and the body to the side air bag
impact sensors or the airbag control unit. These pulses could, depending on the type of load on the airbag
control unit, be identified on rare occasions as a signal to activate.
Affected vehicles:E46 CKD Mexico Production period: Corresponding to vehicle identification number
selection (April 1999 to August 1999)
Measure: Recode airbag control unit
Procedure: Re-encode airbag control unit:

1. Load DIS or MoDiC III with CD-ROM version 20.0 (only Spanish or US English language
versions) or higher.
4. Select ZCS encoding (”3”).
5. Select E46 series (”7”).
6. Select recoding (”1”).
7. Select airbag (”19”).
8. Follow operator prompting from this point.
After re-encoding is completed. mark the vehicle with a white coloured spot on the right spring strut dome next
to the vehicle identification number (see figure). Apply the identification to the paint, not the transparent film.
N.B.:
1. On rare occasions, the DIS or MoDiC III cannot read the vehicle identification number from the instrument
panel. This is demonstrated by the fault message ”Coding data incomplete or incorrect. CoapiReadFgNr
Error code: 2062”. In these circumstances, carry out a software reset on the instrument panel (test 21) or
a battery reset:
Software reset
With ”terminal R” switched on, press the left panel button for 5 seconds (procedure). Press again for a
short period to call up the test functions. Select test function 19 to unlock the test functions (3 to 21).
After approximately 2 seconds, ”L on” and ”L oFF” appear and alternate in submenu 19.0. When ”L oFF” is
displayed, press the left panel button (test functions unlocked). Then scroll through the test functions
again until test 21, ”rESEt” appears on the display. Now turn the ignition key to position ”Zero” and relock
the test functions.
Battery reset
Disconnect battery with ignition switched off, briefly touch both cable ends together and reconnect the
battery.
Now switch the ignition back on and delete any fault codes that may be present. The encoding can now
be carried out.
00 65 40 01 00
Recode airbag control unit:
Labour 3 FRUs
Warranty type 1
Warranty level 1
65 03 00 (573)
Side airbag: fault code 05/06 (MRS3) or fault code 08/09 (MRS2)
E46
Complaint: The airbag warning lamp is activated.
The following fault codes can be stored in the airbag control unit fault memory (MRS -
multiple restraint system):
"05 - front left-hand side airbag" (MRS3)
"06 - front right-hand side airbag" (MRS3)
Cause: Increased contact resistance due to deposits on the airbag contact pins in the door wiring
harness connector on A-pillar.
Manufacturing period: start of series production until January 2000.
Procedure: In the event of a customer complaint:
1. Connect up the DIS tester or MoDiC to the vehicle and read off the airbag control unit fault
memory.
2. If the cause of the fault is "Side airbag, resistance too high", replace the airbag contact pins in the
respective A-pillar connector as follows:
3. Disconnect vehicle battery.
Comply with safety regulations for handling airbag system components.
Repair Instructions 32 34 ...
4. Remove the side trim in the footwell on the affected A-pillar.
Repair Instructions 51 43 070 or 51 43 075
5. Remove the door wiring harness connector from the A-pillar and unplug the connector.
6. Unpin the two airbag contacts (pin 19 and pin 20) from the wiring harness connector housing on the
vehicle side.
Please refer to "Fitting and removing contacts from different connector systems".
7. Expose the wound up pair of airbag wires until a suitable area is available to attach butt connectors. This
must not be a moving or mechanically stressed area of the wiring harness.
8. In this area, cut through the airbag wires at points approx. 30 mm offset and strip the ends of the wires.
Please refer to "Cutting and stripping wires".
9. Connect up the two contacts from the repair cable "Repair cable for A, B-pillar/control unit" in the
connector housing sockets previously vacated. The allocation of the repair cable is not important.
10. Wind up the pair of repair cable airbag wires.
11. Shorten the pair of airbag wires in the repair cable to the same remaining length to the vehicle-side wiring
harness. Strip the ends of the wires and connect them on the vehicle wiring harness with butt
connectors and shrink-fit hose. The two butt connectors must not be immediately adjacent to each
other.
Please refer to "Repairing a plug connector on a wiring harness using a butt connector".
12. Wind up the wires again. The untwisted length must not exceed 40 mm.
13. Fix the interface (butt connector) in position with insulating tape to prevent the cable from untwisting.
14. Remove the door trim panel.
15. Unpin the two airbag contacts (pin 19 and pin 20) from the wiring harness connector housing on the door
side and cut off the contacts.
16. Tie back the cables remaining on the wiring harness (door side) with insulating tape.
17. Route the twisted repair cable "Repair cable for A, B-pillar/side airbag" through the rubber grommet and
into the inside of the door. It is easier to thread the cable through if you use a piece of wire as a tool.
18. Connect up the two contacts from the repair cable in the connector housing sockets previously vacated.
The allocation of the repair cable is not important. To ensure that there is no mechanical stress, make
the wires on the connector housing of an adequate length.
19. Secure the repair cable to the door wiring harness and route it to the side airbag. Cut off any excess
length on the repair cable at a suitable point (at offset points). Strip the ends of the wires.
20. Cut both cables from the side airbag at a suitable point, strip the ends of the wires and connect them to
the repair cable using butt connectors and shrink-fit hose.
23. Tie back the cables remaining on the wiring harness with insulating tape.
24. Reinstall the removed parts.
25. Clear the airbag control unit fault memory.
Repairs on the airbag wiring harness must only be performed using the following special tools (order numbers):
- hand pliers (61 9 041) with die (61 9 042)
- wire strippers with wire cutter (61 9 043)
- "repair range 4" for vehicle electrical system (61 9 020)
Please refer also to Repair Instructions "Repairing airbag wiring"
Repair Instructions 61 00
Important:
Hotline Information bulletin 653617000 is rendered invalid with the publication of this Service
Information bulletin.
Repair cable for A, B-pillar / 61 12 8 386 368 1
control unit
side airbag
Butt connector 61 13 8 353 746 4
Shrink-fit hose 61 13 1 379 833 4
Install repair cable for side airbag on driver's side:
Labour 21 FRUs 4-door models

22 FRUs 2-door models
Install repair cable for side airbag on passenger-side:

Install repair cable for side airbag on driver's and passenger-side:




Warranty type 1


65 05 00 (590)
Software errors in navigation system
E38, E39, E46, E53 with navigation system (option 609) E46, E52 with radio
navigation system (option 606)
Complaint: The following software errors may occur intermittently or permanently in the navigation
system or when operating functions by means of the on-board monitor or the radio
navigation control panel:
1. The words "Enter code" appear on the monitor when the ignition is switched on.
2. Telephone numbers from a list of "Points of Interest" for Italy are dialled with an incorrect number.
3. Existing TMC traffic news is intermittently deleted (symbols in the route map)
4. The menu item "Audio" intermittently fails to appear in the display (E52 only).
5. System reset when selecting a road junction from a list with numerous entries (USA only).
The complaints described above are not valid reasons for exchanging the navigation computer.
Software errors that have already been able to be eliminated in an earlier version of the operating software
are not mentioned in this Service Information bulletin. You can find a list of these errors in the following Hotline
Information bulletins:
"Operating software BMW Navigation System V 08" No.: 652950000
"On-board computer data not displayed in full" No.: 653271000
or Service Information bulletins:
"Software errors in navigation system" No.: 65 03 99 (423)
A description of the new functions is given in the Diagnosis and Encoding Information bulletin IDC 011/00-1
(available from approx. June 2000).
Cause: Software errors in the operating system for the graphics component of the navigation
computer or for the navigation computer itself (please refer to Enclosure).
Affected vehicles:E38, E39, E46, E53 with navigation system (option 609) or
E46, E52 with radio navigation system (option 606)
Manufacturing period: from the start of series production
Procedure: Compare the customer complaints with the descriptions in the enclosure and verify.
If, by updating the operating software, it is possible to remedy the error in the navigation
system variant affected, this must be done.
The current version of the operating system is available from June 2000.
If no remedy is described here for the error in the navigation system version affected, one will be found and
published at a later date. The customer is then to be informed of the situation.
Parts:
Description Part number Qty.
CD ROM 01 59 9 789 299 1
"BMW Navigation V 15"
Index q
Reimbursement:The remedying of errors whose cause is to be found in previous versions of the

operating software must be dealt with and reimbursed in accordance with the valid
Defect code warranty specifications.
Load navigation system operating software:
Labour 3 FRUs
Labour 2 FRUs
Warranty type 1

Only one of the job numbers listed above may be submitted for reimbursement.
Reimbursement is only possible until September 2001. Reimbursement using the temporary defect codes
from previous Service Information bulletins is no longer possible with the publication of this Service Information
bulletin. The following Service Information bulletins are affected:
- 65 03 99 (423)
- 65 09 99 (463)
- 65 14 99 (513)
The invalidated defect codes are: 65 90 92 14 00, 65 90 95 14 00.

65 15 01 (783)
Audible instructions too loud - tone settings lost
E46 with Radio navigation
(option 606)
Complaint: 1. Audible instructions from the navigation system are very loud when the radio volume is
set to approx. half the maximum volume. In such cases, the volume of the navigation
instructions cannot be changed using the volume control.
2. The individual tone settings selected by the customer (e.g. bass, balance, etc.) are reset to the basic
default setting when the radio is switched off.
Cause: Software error in radio
Affected E46 with Radio navigation (option 606)

vehicles: Manufacturing period: September 2000 to September 2001
Procedure: In case of customer complaint, replace the radio.
Please refer to repair instructions ”Removing and installing / replacing radio control panel
(radio navigation)”,
RA 65 11 040.
Important!
The optimised radio has a modified connector. For this reason, an additional adapter cable and a
new aerial amplifier must be installed.
For how to install the aerial amplifier, please refer to Repair Instructions ”Removing and installing /
replacing aerial amplifier”,
RA 65 24 010 (all models except convertible) or
RA 65 25 050 (convertible)

BMW navigation radio 65 12 6 911 224 1
Adapter lead 61 12 6 913 955 1
Aerial amplifier Please refer to Electronic 1
Parts Catalogue (EPC)
Within the scope of a visit to the workshop - Replace BMW navigation radio and aerial
amplifier, install adapter cable:
Labour 6 FRUs (saloon, coupé, convertible)

7 FRUs (compact)
10 FRUs (touring)
In case of order without additional repair work - Replace BMW navigation radio and
aerial amplifier, install adapter cable:
Labour 7 FRUs (saloon, coupé)

9 FRUs (compact)
11 FRUs (touring)
8 FRUs (convertible)
Warranty type 1

65 07 97 (247)
CD changer: Malfunction
All models with CD changer
Situation: Despite intensive supplier checks, no malfunction can be found with a large number of CD
changers returned under warranty.
These CD changers are often returned without the CD magazine and in an unsuitable
transport condition while bearing the label ”Failed”. This generally results in the CD changer being classified as
kFg (no fault found) and returned to the dealer. The warranty claim is rejected.
Important notes for CD changers in the vehicle:
As opposed to CD changers in the home, mobile CD changers are subjected to an extremely wide range
of different influences.
The mechanics must be spring-mounted, which (depending on the manufacturer) is provided by a rubber
damper with an air reservoir or an oil damper. For this reason the transportation retainers must always be
removed before installing the CD changer.
The CD changer can hold and properly position 12 cm standard CDs. Please note that the CDs must not
be too thick as well as deburred around the central hole or outer edge.
Transparent CDs and CDs with asymmetrical dimensions can no longer be reliably detected and
positioned by the laser beams in the CD changer. Asymmetric CDs cause the CD magazine to jam in the
CD changer. The magazine can no longer be removed from the changer.
Ensure the spring suspension is set correctly for replacement units. Depending on the installation
position, set the ”installation position” on the CD changer to horizontal or vertical. On the E36 Compact,
set the ”installation position” on the CD changer to 45°.
The magazine compartment must be closed at all times to prevent dust and other contaminants from
entering the CD changer and impairing the system function.
Ensure all CDs are clean to avoid soiling the laser and impairing the CD changer function.
No guarantee is given that CDs burned at home will be played. The quality of the audio playback depends
on the quality of the blank CD, the CD burner and parameters selected when burning the CD.
The CD changer is not suitable for rewritable CDs (called CD-RWs).
Affectedvehicles:All BMW models with CD changer (optional equipment 672)
Procedure: In the event of a customer complaint, always diagnose the exact cause of the failure
before replacing the CD changer.
As the fault cause may be a faulty CD magazine or caused by faulty CDs/homemade CDs,
always test the system with a new CD magazine and different CDs to see if the customer complaint is
reproduced.
Note for obligatory return markets:
For the warranty parts inspection, it is absolutely mandatory that the CD changer is always returned together
with the customer's original CD magazine and the device connecting lines. The CD changer must be fitted with
transportation retainers when returned: A CD changer without any form of transportation retainer may be
damaged during transport.
Please return the CD changer in the original packaging of the replacement CD changer.
CD changers without a CD magazine and transportation retainer will be returned immediately by the
Warranty Parts Centre (GWTZ) and the warranty application will be rejected.
Furthermore, ensure that each CD changer or CD magazine returned is accompanied by the blue
complaint and repair documentation completed in full(part number: 01 30 9 789 549). The number of CDs
in the changer must also be recorded in the repair documentation.
65 12 02 (902)
Copy-protected audio CD cannot be played
E31, E32, E34, E36, E38, E39, E46, E52, E53, E65, E66, E85
Complaint: Audio CDs with the label:
”This CD is copy-protected and cannot be played on a PC”
can be played only scrambled or not at all in the vehicle.
Affected vehicles:
All (with CD player)
Production period:
From series launch
Cause: Copy-protected CDs do not correspond to a certain guideline that CD manufacturers must
comply with. Digital signal processing as takes place when copying CDs with the PC is
prevented.
The above problem may occur as the signal processing required to playback audio CD data takes place by
means of digital/analogue conversion in the vehicle.
Remedy: Return the CD to the CD dealer and complain! These CDs should be recalled from the
market as is already the case in Great Britain.
This is not a problem that BMW AG can be blamed for but rather it is solely due to CD
manufacturers who do not comply with the audio CD standard.
Procedure: ---
65 02 99 (408)
Cruise control intermittently inoperable
E38, E39, E46
Situation: The cruise control system can intermittently not be activated.
This fault can only occur if the ignition is switched on twice within the space of 6 to 30
seconds before starting the journey.
Affected E38, E39, E46 with cruise control (option 540)
vehicles: Manufacturing period: November 1998 to January 1999
Procedure In case of customer complaint, replace the brake light switch.
(Please refer to Repair Instructions 61 31 310)
Parts:
Brake light switch 61 31 8 372 647 1
Spare parts supply is not affected.
61 31 90 14 00
Replace brake light switch:
Labour Please refer to flat-rate manual
Warranty type 1

Reimbursement is limited to 36 months/100,000 km and only possible
until December 2000.
65 13 00 (641)
must be observed.
a retrofit kit.
switch.

Attention!
Attention!
Key:
introduction
Enclosure 5.
Enclosure 6.
production
production
production
production
production
production
E60/E61 up to 08.05 1 1 1
E60/E61 From 09.05 2 2 1
E63 up to 08.05 1 1 1
E63 From 09.05 2 2 1
E64 up to 08.05 1 1
E64 From 09.05 2 2 1
production
production
production
E83 up to 08.04 1 1 1
E83 From 09.04 2 2 1
E84 from series 2 2
production
production
E87 From 03.05 2 2
E89 from series 2 2
production
E90/91/92/93 from series 2 2
production
R50/R53 up to 06.04 1 1 1
R50/53 From 07.04 2 2 1
R52 from series 2 2
production
production
production
production
production

Note:
E53 1
with option 230
E60/61/63/64 1
E65/66 1
E81/82/87/88 1
E83 1
E84 1
E85/86 1
E89 1
E90/91/92/93 1
MINI from R55 1
BMW F-Series 1
BMW i 1
2.
4.
vehicles 5.
warning 7
Note:
deactivated.
2004), R50,53 (to July 2004) OHNE
R52

limiter (EPC)
warning stickers)
65 07 04 (136)
Fault rectification for navigation system operating software ”BMW Navigation V24.0”
E46 with radio navigation system (option 606)
Complaint: The following faults can occur intermittently or permanently in the navigation system:
E46 with radio navigation system (option 606)
Slow reaction to movements of the rotary knob, principally when scrolling through lists (the cursor ”sticks”).
This can cause incorrect operation.
This complaint does not constitute a valid reason for exchanging the navigation computer.
Cause: Software error in navigation system operating system.
Affected vehicles:E46 with radio navigation system and DVD navigation computer.
Manufacturing period: from September 2002
For all other vehicles, installing the operating software V24.0 will not eliminate the
fault!
Procedure: In case of customer complaint, update the operating software. To do this, use CD ROM
”BMW Navigation V24.0”, index o, with part number 01 59 0 141 891.
Note:
For procedure for programming the navigation computer, please refer to IDC 043/04-8.
Further information on working on the navigation system can be found in the Repair Instructions.
Note:
The operating software must always be updated before exchanging a computer. If the component
is returned, it is essential that the complaint-repair documentation is correctly completed.
Navigation computers returned due to obligatory return, which do not have the current software
status installed will be returned to the workshop concerned and reimbursement through warranty
will be rejected.
65 90 91 02 00
This defect code is not contained in the official Defect Code
Catalogue but has been included in the system, thus enabling warranty claims to be processed.
As part of a visit to the workshop - Load navigation system operating software:
Labour 2 FRUs
In case of order without additional repair operations - Load navigation system

operating software:
Labour 3 FRUs
Warranty type 1

Only one of the job numbers given may be submitted for reimbursement.
Reimbursement is limited to 36 months/100.000 km and is only possible until July 2007.

65 06 04 (126)
Master document for airbag/belt tensioner
All model series
Situation: The volume of information about the airbag/belt tensioner topic has greatly increased in
the past few years due to technical innovations. To simplify the targeted search for
information, this document contains a summary of all important information about the
handling of airbags/belt tensioners at the dealer's operation and can be accessed directly using hotspot.
Procedure: Search for a topic in the table below and select a document with hotspot.
1. Fault memory / airbag indicator light

"Airbag with seat occupancy detection" SI 65 04 96 (064)
Side airbag: Troubleshooting 05/06 (MRS3) or fault code SI 65 03 00 (573)
08/09 (MRS)"
"Airbag fault code 01/0D (MRS3): Driver's airbag" SI 65 07 00 (603)
2. Repair
"Repair of airbag systems that have been activated" SI 65 09 89 (126)
"Airbag, repair instructions for ignition circuits" SI 61 01 99 (397)
"Airbag: Repair instructions for the ignition circuit, belt SI 61 01 03 (952)
tensioner and/or side airbag"
"Airbag control unit replacement" SI 65 10 96 (129)
3. Deactivation / recoding
"Deactivated side airbags in the rear passenger SI 65 07 99 (442)
compartment"
"Recode the airbag control unit" SI 65 37 01 (000)
"Check side airbag impact sensors and recode the SI 65 39 01 (000)
airbag control unit"
"Deactivation or reactivation of airbags / belt warning SI 65 13 00 (641)
sound"
65 01 05 (236)
New audio test CD for complaints about sound system playback
All series
Situation: In case of customer complaints about sound quality when playing CDs or DVDs, it can be
extremely difficult to diagnose whether it is a problem with the drive or a problem with the
disc itself.
This is in part because customers are increasingly using discs of poorer quality (e.g. self-recorded CDs), which
either cannot be played or can only be played poorly.
To help you distinguish, an audio test CD is now available.
This audio test CD should be used to analyse the following complaints on the customer's vehicle:
CD/DVD not accepted
CD/DVD jumps
CD/DVD cannot be read
CD/DVD operation interrupted permanently or intermittently
Note:
The audio test CD contains a track with built-in faults, but which the sound system should play
back correctly.
Affected All model series with original BMW/MINI audio systems with CD/DVD drive or CD/DVD
vehicles: changer.
Procedure: Insert the audio test CD in the drive for which the customer has complained about the
sound quality.
Important:
The audio test CD provides a sensitive reference.
For this reason, comply with the following guidelines:
Do not touch the CD on the playing surface, only on the edge.
Do not stick labels or write on the CD's surface.
Do not expose the CD to direct sunlight or high temperatures.
Only remove the CD from its protective cover for immediate use.
Play track 12 of the audio test CD and then perform the following fault analysis:
If no faults can be detected in the sound quality, there is no fault in the audio system. Replacing parts will
therefore not achieve the desired result and must not be performed.
Check whether the disc used by the customer is the cause of the complaint.
If there is interference or if the CD jumps when track 12 is being played, the audio system / drive must be
replaced.
Note:
The new audio test CD 01 99 00 33 475 does not supersede audio test CD 01 59 0 004 055
(please refer to SI 65 03 98 381).
The other tracks on audio test CD 01 99 00 33 475 are of no relevance to the analysis and can be
ignored.
65 07 02 (863)
On-board monitor radio fault patterns
E39, E46, E53 with on-board monitor radio (option 602) or with navigation
system (option 609)
Complaint: BMW Business on-board monitor radio only:
1. When FM Autostore is selected by means of the ”Menu” button, this function is aborted
and the radio remains muted until the station or mode button is pressed.
(Production from September 2002 to July 2003)
2. If the radio is switched off at the on/off button before the ignition is switched ”off”, the last AM station
tuned will not be stored. The first frequency in the AM waveband will be stored.
3. Reproduction volume in cassette mode is clearly higher than that in other modes.
4. If the station is changed using the multi-function steering wheel (MFL), the ”ST” display in the instrument
cluster will not change.
BMW Business and BMW Professional on-board monitor radio:
1. When FM Autostore is selected by means of the ”Menu” button, this function is aborted.
(Production from September 2002 to July 2003)
2. When the CD changer is in operation, selecting <<>> in the Select menu and then pressing the Info
button results in incorrect build-up of the right-hand page in the split-screen view. Pressing any other
button rectifies the situation.
3. Very loud whistling noise is audible in all audio modes and in some cases even when the radio is
switched off.
4. Stations saved in memory are lost after prolonged voltage collapses.
5. A short cracking noise may occur immediately before or after a navigation announcement.
6. The function ”AM Autostore” is only possible in AM mode.
7. The function ”SCAN” only goes as far as the first station found.
8. In conjunction with the DSP amplifier (option 677), sound reproduction may be affected by a noise before
or after a navigation announcement or the navigation volume may be briefly too loud.
9. If the radio is switched off using the on/off switch while it is in cassette mode, the cassette drive runs on
and does not stop until the ignition is switched off.
BMW Professional on-board monitor radio only:
1. The list of available stations includes stations that can be selected neither by means of the rotary push
button nor by means of the multi-function steering wheel (MFL). Selection by means of the multi-function
steering wheel is possible only as far as this station in the list and not beyond.
2. If RDS (Radio Data System) is switched off, it is no longer possible to scroll through the list of stations
using the multi-function steering wheel (MFL).
3. If the radio is switched off and back on again at the radio screen, another screen may intermittently
appear. The radio screen appears again when the display button is pressed.
Cause: Software error in on-board monitor radio.
Affected E39, E46 and E53 with on-board monitor radio (option 602) or
vehicles: navigation system (option 609)
Manufacturing period: from September 2001 until July 2003
Procedure: In case of customer complaint, replace the radio receiver.
Please refer to repair instructions ”Removing and installing / replacing radio receiver (radio
navigation or on-board monitor)”, RA 65 11 055.
Parts:
BMW Business on-board 65 12 6 927 911 1
monitor radio:
BMW Professional on-board 65 12 6 934 650 1
monitor radio:
Within the scope of a visit to the workshop - Replace radio receiver:
Labour 2 FRUs (E39 Saloon without CD changer)

5 FRUs (E39 Touring)
3 FRUs (E46 Saloon, Touring, Coupé)
4 FRUs (E46 Convertible)
7 FRUs (E46 Compact)
4 FRUs (E53 without level control)
Labour 3 FRUs (E39 Saloon with CD changer)

5 FRUs (E53 with level control)
In case of order without additional repair operations - Replace radio receiver:
Labour 4 FRUs (E39 Saloon without CD changer)

6 FRUs (E39 Touring)
5 FRUs (E46 Saloon, Touring, Coupé)
6 FRUs (E46 Convertible)
8 FRUs (E46 Compact)
5 FRUs (E53 without level control)
Labour 5 FRUs (E39 Saloon with CD changer)

6 FRUs (E53 with level control)
Warranty type 1


65 15 99 (521)
Position inaccuracies in navigation system
E38, E39, E46 with navigation system option 606/609
Complaint: Fault pattern 1:
Incorrect distances are occasionally indicated at crossroads or motorway exits (e.g. 50 or
more metres when the vehicle is already at the crossroads or motorway exit).
Fault pattern 2:
Vehicles with navigation system (option 609)
The position cursor in the map drifts away from the road and traces alongside it. In extreme cases, the position
cursor may even stray at an obtuse angle away from the road, not corresponding to the route driven.
This causes incorrect navigation instructions, for example "Please turn around", "Turn left/right at the next
crossroads", "You are now leaving the recorded road network" etc. to be given.
The following faults may also occur in conjunction with these complaints:
implausible guidance instructions,
longer reaction times for the navigation system,
delayed buildup of map image or
delayed instruction to turn
Vehicles with radio navigation system (option 606)
As there is no map display, it is primarily the faults
implausible guidance instructions,
longer reaction times for the navigation system
which occur. Moreover, the road direction arrow frequently disappears.
In its place, the target direction arrow appears with disproportionate frequency.
The following complaint must not be mistaken for the above fault patterns:
The route intermittently runs in a loop. This can cause the route guidance to run in an implausible direction. This
effect is however limited locally and does not occur over a lengthy period.
Please refer to Service Information bulletin "Software errors in navigation system"
SI 65 14 99 (513)
Cause: Concerning fault pattern 1:
This fault pattern is an intermittent calibration error in the calculation of the journey
distance. This takes effect in the form of a distance offset only after driving a long straight
section.
In general, if appropriate complaints are received, it should be noted that the distances given usually refer
to the centre of the crossroads
to the point where the junction begins.
A turning lane is not considered a junction.
At points where the inaccuracy can be reproduced, the fault is in the data material of the CD roadmap.
Concerning fault pattern 2:
This fault pattern is an intermittent faulty correction value for the temperature-dependent drift of the rotation
rate sensor (gyro) in the navigation computer. This characteristic has an unfavourable effect in navigation
computers whose rotation rate sensors have higher drift values in certain temperature ranges.
The rotation rate sensor (gyro) is built into the navigation computer and supplies an output signal that is
proportional to the angular velocity of the vehicle. This signal is subject to thermal drift, which
must not exceed certain tolerances, and
must be compensated for by software algorithms in the navigation computer.
As the rotation rate sensor detects angular velocity between uphill and downhill sections in the same way as it
does in corners, this complaint also occurs when driving on winding mountain roads. Moreover, a comparison
with the roadmap is made difficult by the 2-dimensional projection of the
3-dimensional terrain. This is a conceptual shortcoming and does NOT constitute a fault.
Affected E38, E39, E46 with navigation system (option 609) or
vehicles: E46 with radio navigation system (option 606)
Manufacturing period: September 1997 to September 1999
Procedure: Concerning fault pattern 1:
Check with the customer precisely how the fault makes itself shown.
If possible, exact details of the geographical location and the distances given should be
recorded.
If the problem can be reproduced at certain crossroads:
Complete correction form as described in SI 65 04 97 (214) and return it to the subsidiary responsible for your
country.
The problem is caused by an inaccuracy in the data material of the CD roadmap. The notes on the correction
form can be used by the publisher of the CD roadmap (NavTech) to check and correct the data.
If the problem cannot be reproduced at certain crossroads:
Check the navigation system operating software and update as necessary.
The calibration algorithms have been improved from the following software statuses:
"28" for navigation system (CD BMW Navigation V12),
"25" for radio navigation system (CD BMW Navigation V11).
The operating software is shown in the "Settings" menu:
Current values are, e.g.:
"2-1/30" for navigation system (option 609)
"2-2/40" for radio navigation system (option 606)
Here, the numbers "30" and "40" stand for the respective software status and correspond to current version of
the operating software "CD BMW Navigation V14". Please refer also to IDC 028/99-10.
No further improvement to the calibration algorithms in the operating software is available at present. It must
be taken into consideration that all sensors, all measured values and the roadmap data material contain
inaccuracies which can lead to deviations from the calculated position. This is a conceptual shortcoming and
does not constitute a fault.
All navigation systems which compute a position in this manner and which have the same sensors (rotation
rate sensor, distance sensor with automatic calibration using GPS and map-matching) are subject to the same
fault sources.
Concerning fault pattern 2:
Check with the customer precisely how the complaint makes itself shown. Here, it is of particular importance to
differentiate whether the position cursor "only" drifts slightly away, or whether it moves clearly away from the
road.
On vehicles with radio navigation system, it should be recorded using known digitalised roads whether the
target direction arrow appears disproportionately frequently and a long time, or "only" intermittently over
relatively short stretches.
If the position cursor only drifts away slightly or the target direction arrow only appears intermittently for short
stretches on digitalised roads:
Check the navigation system operating software and update as necessary.
The calibration algorithms have been improved from the following software statuses:
"28" for navigation system (status CD BMW Navigation V12),
"25" for radio navigation system (CD BMW Navigation V11).
If the software status read off already complies with the required minimum level, or if the position cursor drifts
widely away, or if the target direction arrow appears disproportionately frequently or a long time:
Replace the navigation computer, load the current version of the operating system and then encode.
In such cases, the drift rate of the rotation rate sensor is outside tolerance so that correction algorithms in the
software can no longer make the necessary correction.
A precise fault description must be entered on the warranty parts tag, along with the number of this
Service Information bulletin
(65 15 99 (521)). If this label is not attached to the part, the navigation computer cannot be approved as a
part that can be replaced under warranty.
In Germany:
The returned navigation computer must be accompanied by a completed fault record form giving details of the
complaint. Please refer to Service Information bulletin "Complaint and repair documentation: radio, audio,
navigation, telephone"
SI 65 13 99 (487).
Parts:
CD ROM
01 59 9 789 299 1
BMW Navigation V14
This CD ROM contains the software for the navigation computer.

It cannot be reimbursed via warranty.
E38, E39, E46 with
option 609:
Before May 1999:
Navigation computer 65 90 6 908 313 1
After May 1999:
E46 with option 606:
Before May 1999: 65 90 6 908 314 1
Navigation computer
After May 1999:

65 90 96 18 00

Labour 2 FRUs
Replace and encode navigation computer, load operating software:
Labour 3 FRUs E38/E39

3 FRUs E46 coupé and saloon
5 FRUs E46 touring
Labour 3 FRUs
Replace and encode navigation computer, load operating software:
Labour 5 FRUs E38/E39

5 FRUs E46 coupé and saloon
7 FRUs E46 touring
Warranty type 1
Warranty stage 1
A warranty claim can be made under only one of the above job numbers.
65 13 02 (910)
Problems when installing navigation software
E38, E39, E46, E52, E53, E65, E66 with radio navigation (option 606) or
navigation system with on-board monitor (option 609)
Complaint: The following problems may occur while the navigation software is being copied to the
navigation computer:
The message ”CD defective” appears.
The software cannot be copied.
The message ”Fault during programming” appears. The software cannot be copied.
The message ”The system is restarting” appears. The software cannot be copied.
The installation process is aborted. The on-board monitor or the display in the MIR is dark and the
power LED in the navigation computer is off. The CD is not ejected - it remains in the navigation
computer even if the eject button is pressed.
These fault patterns can occur if the navigation software CD has signs of use or slight scratches. An exchange
of the navigation computer is not permissible.
Affected vehicles:E38, E39, E46, E52, E53, E65, E66 with radio navigation (option 606) or navigation
system with on-board monitor (option 609)
E38, E39 from September 2000
E46 from June 2000
E52 from September 2000
E53 from December 2000
E65 from November 2001
E66 from March 2002
Procedure: If the navigation software CD is ejected automatically or when the eject button is pressed
(points 1 - 3):
Insert a new, unused CD and restart the installation process. Do not use the CD on which the fault
occurred any longer.
If the navigation software CD is still in the computer (point 4):
Remove the navigation computer (please refer to Repair Instructions 65 90 510 ”Removing and installing /
replacing navigation computer with CD drive”).
Unplug the voltage supply (blue connector).
Reconnect the voltage supply and immediately press the eject button repeatedly until the CD in the drive
is ejected.
Insert a new, unused software CD and restart the installation process (for procedure for programming
navigation computer, please refer to IDC 031/02-1). There may be a delay of about 2-3 minutes before
the screen for software installation appears and the process starts. Do not use the CD on which the fault
occurred any longer.
After the software has been successfully installed, reinstall the navigation computer.
Note:
These problems occur with scratched navigation software CDs. For this reason, it is advisable to always have
two software CDs to hand.
One is for daily use and the other remains unused as a backup.
If one of the above faults occurs with the first CD, it should no longer be used and the backup CD used from
then on.
At the same time, a new software CD should be ordered from the parts sales department as a new backup.
The situation described in this Service Information bulletin cannot be reimbursed under warranty as there
is no technical defect present.
65 05 04 (109)
Problems with audio/navigation CDs/DVDs
All series
Situation: In recent years, the actions of the customers with regard to audio and navigation CDs and
DVDs used in the vehicle has changed greatly. Customers are increasingly using not only
purchased, pre-recorded CDs/DVDs, but also data carriers that they have recorded
themselves, and which could cause problems when used in a vehicle. Purchased data carriers may also have
a copy-protect function.
The following complaints may occur when such data carriers are used:
1. A CD is in the drive but is not recognised / cannot be played.
2. Reproduction is distorted.
3. The CD jumps, there are gaps in the sound when music tracks are played.
4. The CD always played correctly in the past, but not any more.
5. Not all CD tracks are played (home-recorded CDs).
6. The CD plays without any problem on indoor equipment (e.g. stereo system), but not in the car.
7. Problems when installing navigation software
8. Problems with the readability of the navigation road map.
Procedure: If one or more such complaints occur, the CDs/DVDs used by the customer should be
checked for the following criteria:
Are home-recorded or copy-protected data carriers being used?
Are the CDs/DVDs heavily worn, scratched or dirty?
If this check indicates that the problem is caused by the media used by the customer, no parts are to be
replaced - this is not a problem relevant to warranty.
Replacing the radio, CD changer or navigation computer will not bring about a lasting solution, the complaints
will occur again. In such cases, the customer should be approached with the arguments laid out in the points
below.
Note:
The CD drives installed in BMW and MINI vehicles are able to play any and all CDs available on
the market that comply with the recognised standard for audio CDs/DVDs (the so-called ”Red
Book Standard”). Home-recorded CD-R and CD-RW can also be played without problem,
providing they meet certain minimum quality requirements (the so-called ”Orange Book
Standard”).
Explanatory information about the complaints described by the customer
Concerning complaints 1 to 5 and 7, 8:
The quality of the burned media is determined by various factors:
Quality of the blanks used (coating)
Depending on the quality of the blanks used, home-recorded media age relatively quickly, a process that
is often not visible from the outside. Cheap blanks can often no longer be played after just 1 - 2 years.
The writing speed selected for burning
The faster poor quality blanks are recorded, the poorer the result will be
Sensitivity of home-recorded CDs to scratches and dirt
The reverse (with a label) is the actual medium onto which the data is burned. Damage such as scratches
caused by the customer's own labelling of the CD can thus have a direct negative effect on readability.
Reading error
It is of course possible for reading errors to occur on original CDs. Scratches, dirt etc. also attach their
surfaces.
Concerning complaints 1 to 4
Unfortunately, not all manufactures of data carriers adhere to the recognised standards for the quality of
the basic media and data organisation. In the case of the known copy-protection mechanisms, the
manufacturers actually violate them deliberately.
BMW permanently strives to ensure that all regularly available media can be played. In individual cases
however, not every violation of standards can be provided for.
Claims arising from copy-protected CDs that cause reading errors should be submitted to the CD dealer.
These problems cannot be attributed to BMW AG, but rather solely to the CD manufacturers who do not
adhere to agreed audio CD standards.
Concerning complaint 5:
Depending on the computer performance, quality of blanks used, etc., problems may develop meaning
that not all data are fully and correctly recorded on the data carrier during the burning process.
The consequence of this is that only a fraction of the data needed can be reproduced (e.g. the tracker
only finds the first two of a series of recorded CD tracks).
The requirements of equipment concerning temperature range, sensitivity to vibrations and dirt that are
needed for use in motor vehicles cannot always be achieved despite maximum efforts. For this reason, a
certain limitation in function compared to indoor equipment must be accepted.
Please refer to Service Information bulletin 65 13 02 (910).
65 11 00 (617)
Radio CD 43: CD is not ejected
E46
Complaint: CD is not ejected from the radio.
Cause: Production residue on the wooden finisher in the area of the radio.
Affected E46 with fine wood finish (option 438) and Radio Business CD (option 662)
vehicles: Manufacturing period: September 1998 to March 2001 (production period extended from
October 1999 to March 2001).
Remedy: Remove injection burr from the wooden finisher in the area of the radio.
Procedure: In event of customer complaint, the wooden finisher in the area of the radio must be
reconditioned:
if the radio finisher strip is drawn over the CD slot (see illustration).
Take off the wooden finisher and remove the residue from the central area (middle) of the aluminium carrier
section with a triangular scraper. Bevel the edges. Install the wooden finisher with pressure towards the
driver's side.
Note: As a basic rule, only standard CDs without additional adhesive labels may be used.
Do not rework the wooden finisher in the area of the radio:
if the radio finisher strip runs parallel with the wooden finisher (see illustration).
If the problem is not rectified, an internal fault in the radio can be assumed.
65 10 91 29 00Remove production residue from the wooden
finisher.
Labour 3 FRUs
Warranty type 1

65 02 98 (326)
Radio country code
E31, E32, E34, E36, E39, E46, E53 with BMW Business CD radio (global
receiver)
Situation: The BMW Business CD radio (global receiver) is designed for reception in all regions of
the world.
Effect: An exchange radio or an original radio drawn from the BMW parts sales department must
be set in the vehicle to the appropriate country (region Europe, USA, Canada, Oceania,
Japan) for the following reasons:
1. A display of "foreign" (i.e. unused) frequency ranges must be suppressed.
2. Poor reception due to insufficient frequency increments during station search must be avoided.
3. Missing or unknown softkeys must be configured.
Affected E31, E32, E34, E36, E39, E46, E53

vehicles:
Action: Set the region.
Procedure: Proceed as follows the first time an exchange radio or original radio is switched on:
1. Install the exchange radio in the vehicle.
2. Switch the radio on.
3. The words "NO AREA" will appear in the display
(only the first time the radio is switched on).
4. Switch on to the desired region
("Europe", "USA", "Canada", "Oceania", "Japan").
- on the E46 radio or DIN units (e.g. E36) with "Station key 1".
- on the E39 radio with the first softkey (AREA).
5. Switch the radio off (the AREA displayed/selected will be stored).
The "AREA" menu can also be set using service mode. To switch to service mode, switch the radio on and
within 8 seconds press and hold button "m" until the serial number appears in the display.
To change an already set region:
On the E46 radio, E39 radio and DIN radios (e.g. E36):
1. Switch to service mode. To switch to service mode, switch the radio on and within 8 seconds press and
hold button "m" until the serial number appears in the display.
2. Press the "+ button" repeatedly until the set "AREA" (e.g. AREA EUROPE) is displayed.
3. On the E46 radio and on DIN radios, press station key 1, on the E39 press the softkey AREA repeatedly
until the required AREA is displayed.
4. Switch the radio off (the AREA displayed/selected will be stored).
Depending on the selected region, a CODE input may be required immediately after completing this
adjustment.
The 5-digit radio code is validated when the region USA is selected.
Customer complaints arising from a missing country code cannot be claimed under warranty.
00652001/0598
Radio navigation system: Load operating software
E46 with radio navigation
Complaint: The following faults can occasionally occur with the radio navigation system:
- After activating the ”Route guidance” menu item, there is no route guidance . No turning instructions or
remaining distances are given.
- The message ”You are leaving the digitised area” is not given, despite the fact that the planned route
passes through a non-digitised area.
- When leaving the planned route in a non-digitised area, first of all a ”Direction arrow” (arrow which points to
the destination as the crow flies) appears. This disappears shortly afterwards. No visual indicators are
given until the vehicle rejoins a digitised road.
- After activating route guidance and then switching off the vehicle: between restarting the journey and
reaching a noteworthy location, only the ”Direction arrow” is displayed. Only then does the correct ”Route
arrow” appear. This fault mainly occurs on motorway journeys.
Cause: Incorrect radio navigation system operating software version ”V 1.9” (or lower).
Vehicles concerned:E46 with radio navigation system (SA 606) Production period: Corresponding to list
of vehicle identification numbers (Series introduction until March 1998)
Remedy: Load approved operating software ”V 2.1”. This can be found on the current ”BMW
Navigation V 08” CD-ROM (see Information Diagnosis and Coding IDC 007/98_1 from
May 1998).
Procedure:
1. Turn ignition key to position 1 (terminal ”R” on) and wait until the navigation system is
operational.
Note: Do not perform any diagnosis during the following procedure. Ensure the voltage supply is steady,
i.e. do not switch any consumers on.
2. Remove the CD road map from the navigation computer.
Insert the ”BMW Navigation V 08” CD-ROM.
After a few seconds, a bar appears on the screen that is progressively filled in. The software version and
the languages loaded are displayed.
3. Now remove the operating software CD first and then finish the loading process by pressing the rotary
push-button on the on-board computer. ”O.K.” is displayed.
4. Re-insert the CD road map in the navigation computer.
Note: The navigation system does not have to be recalibrated.

”BMW Navigation V 08” CD- 01 59 9 789 299 1
ROM
The operating software CD is sent free of charge (see Information Diagnosis and Coding IDC 007/98_1). Each
dealer in the distribution network receives this operating software CD, which can then be used as many times
as needed to load the operating software.
00 65 20 01 00
Load navigation operating software
Labour 3 FRUs
Warranty type 1
Warranty level 1
65 14 01 (782)
Reception interference in on-board monitor radio
E39, E46, E53 Euro with on-board monitor radio (option 602) or navigation
system (option 609)
Complaint: With the on-board monitor radio, intermittent reception interference may occur in the lower
radio frequency range (up to approx. 92 MHz) or at higher temperatures across the entire
radio frequency range.
Cause: Component tolerances in the hardware of the radio.
Affected E39, E46, E53 with on-board monitor radio (option 602) or navigation system (option 609).
vehicles: Manufacturing period: September 2001 to October 2001
Procedure: In case of customer complaint, replace the radio receiver.
Please refer to Repair Instructions ”Removing and installing / replacing radio receiver”,
RA 65 11 055.
Parts:
BMW Professional on-board 65 12 8 385 898 1
monitor radio
Labour 2 FRUs (E39 saloon)

5 FRUs (E39 touring)
3 FRUs (E46 saloon, touring, coupé)
4 FRUs (E46 convertible)
7 FRUs (E46 compact)
5 FRUs (E53)
Labour 4 FRUs (E39 saloon)

5 FRUs (E46 saloon, touring, coupé)
6 FRUs (E53)
Warranty type 1


00652501/0199
Retrofit ITS head airbag holder
E46
Situation: Endurance tests have shown that the installation tolerance between the gas generators
of the ITS head airbags and the neighbouring components varies within a restricted
production period.
Effect: With increasing mileage/km, this could lead to rattling noises when driving on an uneven
roadway.
Affected vehicles:E46 Production period for: According to the list of vehicle identification numbers
(September 1998)
Measure: An additional bracket must be installed on both ITS head airbags.
Procedure:
- Disconnect battery.
- Remove and install light switch unit – driver’s side
See repair instructions 61 31 033.
- Remove and install side fresh air grille (dashboard).

- Remove and install steering column shroud, top and bottom.

See repair instructions 32 31 003 and
32 31 020.
- Remove and install glove box.

- Remove and install cover for glove box, top.

- Remove and install fresh air grille (dashboard), front passenger side.
- Remove left and right expanding clips at bottom of dashboard.

- Pull off connectors from both gas generators.
- Pull dashboard outwards at the bottom on both sides.
- Install both additional brackets (see figure). Position holder (1) on the bottom gas generator and screw into
place on the gas generator mounting with a new self-locking nut (2).
Parts:
Additional bracket, left 72 12 7 002 285 1
Additional bracket, right 72 12 7 002 286 1
Self-locking nut 51 21 1 803 363 2
Expanding clip for 51 45 8 257 986 2
dashboard, bottom
00 65 25 01 00
Install both additional brackets:
Flat rate units 11 FRUs - 320 to 328i US 11 FRUs - 318i ECE 12 FRUs - 320d to 328i ECE
Warranty type 1
Warranty level 1
00654101/0400
Retrofitting adapter cable for navigation computer
E46 Saloon/Coupé/Touring
Situation: Resistances are fitted in the input of the navigation computer. Due to excessive switch-on
current peaks, these resistances may be overloaded and, depending on the frequency of
use of the vehicle, may ultimately be destroyed. This would lead to a total failure of the
navigation system.
Figure 1
1= Plug connection, adapter cable/wiring harness

2= Resistance module
3= Plug connections, adapter cable/navigation computer
An overloading of the resistances in the navigation computer can be prevented permanently by retrofitting an
adapter cable with an integrated resistance module.
Affected vehicles:E46 Saloon/Coupé/Touring with navigation system (optional equipment 609) or radio
navigation system (optional equipment 606) without Japanese version (optional
equipment 807) Production period: According to vehicle identification number selection
(May 1999 to October 1999)
Measure: Retrofit adapter cable.
Procedure: E46 Saloon/Coupé:
1. Switch off ignition.

2. Remove trim panel in luggage compartment at rear left.
3. Unlock and pull out the navigation computer with special tool 65 5 400. See repair instructions 65 90 510.
4. Check the part number on the adhered label (see figure 2).
Figure 2
If the part number is 65 90 8 385 439, 65 90 8 386 849, 65 90 8 386 850, 65 90 8 386 851 or 65 90 8 386
852: Continue with Point 5. If a different part number from those stated above is specified: The navigation
computer is OK. No further measures are necessary.
5. Disconnect plug connections on navigation computer (white and wine-red connector).
6. Push the connecting cable of the navigation computer to the rear and route it behind the bracket in the
direction of the wheel arch.
7. Connect the adapter cable to the connecting cable.
8. Hold the adapter cable in the direction of the wheel arch and fasten the connector housing and the
resistance module to the audio wiring harness with a cable tie (see figure 3). Then feed the adapter cable
back to the navigation computer bracket. Make sure that the adapter cable can not chafe on body
components.
Figure 3

9. Route the cable end through the navigation computer bracket to the interior.
13. Execute functional check: Select navigation
E46 Touring:
1. Switch off ignition.
2. Open rear left side trim panel.
3. Unlock and pull out the navigation computer with special tool 65 5 400. See repair instructions 65 90 510.
4. Check the part number on the adhered label (see figure 2).
Figure 2
If the part number is 65 90 8 385 439, 65 90 8 386 849, 65 90 8 386 850, 65 90 8 386 851 or 65 90 8 386
852: Continue with Point 5. If a different part number from those stated above is specified: The navigation
computer is OK. No further measures are necessary.
5. Disconnect plug connections on navigation computer (white and wine-red connector).
6. Route the connecting cable of the navigation computer under the bracket in the direction of travel.
7. Connect the adapter cable to the connecting cable.
8. Fasten the adapter cable on the audio wiring harness with a cable tie and then route it again in the
direction of the navigation computer (see figure 4). Make sure that the adapter cable can not chafe on
body components.
Figure 4
9. Route the cable end through the navigation computer bracket to the interior, and connect and lock both
connectors to the navigation computer.
11. Execute functional check: Select navigation
Parts:
Adapter cable 65 90 4 106 111 1
Cable strap 61 13 1 377 134 5
00 65 41 01 00
Check part number:
Flat rate units 5 FRUs for E46 Saloon/Coupé 3 FRUs for E46 Touring
Check part number and retrofit adapter cable:
Flat rate units 6 FRUs for E46 Saloon/Coupé 5 FRUs for E46 Touring
Warranty type 1
Warranty level 1
65 05 00 (590)
Software errors in navigation system
E38, E39, E46, E53 with navigation system (option 609) E46, E52 with radio
navigation system (option 606)
Complaint: The following software errors may occur intermittently or permanently in the navigation
system or when operating functions by means of the on-board monitor or the radio
navigation control panel:
1. The words "Enter code" appear on the monitor when the ignition is switched on.
2. Telephone numbers from a list of "Points of Interest" for Italy are dialled with an incorrect number.
3. Existing TMC traffic news is intermittently deleted (symbols in the route map)
4. The menu item "Audio" intermittently fails to appear in the display (E52 only).
5. System reset when selecting a road junction from a list with numerous entries (USA only).
The complaints described above are not valid reasons for exchanging the navigation computer.
Software errors that have already been able to be eliminated in an earlier version of the operating software
are not mentioned in this Service Information bulletin. You can find a list of these errors in the following Hotline
Information bulletins:
"On-board computer data not displayed in full" No.: 653271000
or Service Information bulletins:
A description of the new functions is given in the Diagnosis and Encoding Information bulletin IDC 011/00-1
(available from approx. June 2000).
Cause: Software errors in the operating system for the graphics component of the navigation
computer or for the navigation computer itself (please refer to Enclosure).
Affected vehicles:E38, E39, E46, E53 with navigation system (option 609) or
E46, E52 with radio navigation system (option 606)
Manufacturing period: from the start of series production
Procedure: Compare the customer complaints with the descriptions in the enclosure and verify.
If, by updating the operating software, it is possible to remedy the error in the navigation
system variant affected, this must be done.
The current version of the operating system is available from June 2000.
If no remedy is described here for the error in the navigation system version affected, one will be found and
published at a later date. The customer is then to be informed of the situation.
Parts:
Description Part number Qty.
CD ROM 01 59 9 789 299 1
"BMW Navigation V 15"
Index q

Labour 3 FRUs
Labour 2 FRUs
Warranty type 1

Only one of the job numbers listed above may be submitted for reimbursement.
Reimbursement is only possible until September 2001. Reimbursement using the temporary defect codes
from previous Service Information bulletins is no longer possible with the publication of this Service Information
bulletin. The following Service Information bulletins are affected:
- 65 03 99 (423)
- 65 09 99 (463)
- 65 14 99 (513)
The invalidated defect codes are: 65 90 92 14 00, 65 90 95 14 00.

65 05 02 (844)
System does not switch back to original mode after traffic news announcement
E39 with BMW Business radio, E46 with BMW Reverse radio (option 660) or
BMW Business radio (option 661)
Complaint: 1. The increased volume for a traffic news announcement (TP message) is not reset to the
previously set volume at the end of the traffic news announcement.
2. When the system switches to traffic news announcement from CD mode, it does not
switch back to CD mode at the end of the traffic news announcement.
Cause: Software error in radio.
Affected E39 with BMW Business radio, E46 with BMW Reverse radio (option 660) or BMW
vehicles: Business radio (option 661)
E39 with BMW Business radio: September 2000 to August 2001
E46 with BMW Reverse radio: start of series production until March 2002
E46 with BMW Business radio: from start of series production until March 2001
Please refer to repair instructions ”Removing and installing / replacing radio receiver” RA 65
11 030.
Parts:
BMW Reverse radio (E46) 65 12 6 923 842 1
BMW Business radio (E46) 65 12 6 923 844 1
Within the scope of a visit to the workshop - Replace radio:
Labour 3 FRUs
In case of order without additional repair operations - Replace radio:
Labour 4 FRUs
Warranty type 1

Reimbursement is limited to 36 months/100,000 km and only possible until March 2005.

65 03 98 (381)
Test CD for audio systems
All series with CD radio or CD changer
Complaint: Sound quality problems from loudspeakers in all operating modes.
Sound quality problems in complete system
Please refer to Enclosure 1.
- Tweeters
- Mid-range speakers
- Bass speakers
- Bass speaker
External noises during audio playback
- Speakers
- Area surrounding speaker
- Amplifier / radio
Malfunction during audio playback
- Skipping during CD reproduction
- Speakers
- Amplifier / radio
The complaints outlined do not in themselves constitute a reason to replace any audio system
components.
Cause:
- Loose parts(loose securing elements, glass fragments, trim panels and clips in the speaker).
- Speaker not secure or mounting turned beyond pressure point.
- Speaker cover loose.
- Sealing between speaker and trim panel in contact with the speaker diaphragm or is bonded.
- Wires dangling into the speaker or resting on the speaker diaphragm.
- Control units installed near the speaker are loose or generating noises (e.g. due to loose PCBs), which
are triggered depending on the pitch emitted from the speaker.
Affectedvehicles:All model series
Procedure: Prerequisites and pre-adjustments for checking the audio system using the test CD are:
1. Audio system with CD drive present.
2. Battery charged and in working order, use a suitable charger during the check if necessary.
3. Set ”Treble” and ”Bass” to mid-point.
4. Set loudness function (if available) to ”On”.
5. On systems with the surround sound switch (Spacial Sound) or DSP amplifier, switch this off .
6. To carry out the check, the volume must be increased right to the upper limit of the output stage and
then reduced slightly while playing the musical extract on the test CD (Track 17).
Note:
Observe hearing protection regulation and wear hearing protection if necessary!
Only use the test CD in the vehicle together with audio components approved by BMW!
The individual test steps are listed in the appendix of this Service Information bulletin.
Parts: Designation Part number
Test CD for audio systems 01 59 0 004 055
A test CD is included free-of-charge with this Service Information bulletin.
Additional copies may be purchased from parts sales.
65 08 02 (868)
Time intermittently fails to appear in radio display
E46 with BMW Business radio (option 661)
Complaint: If the vehicle is stopped for longer than about 10 minutes and the ignition is then switched
on again, the time fails to appear in the radio display and the radio cannot be operated.
The radio can only be switched on and the time only appears again after the ignition has
been switched off and back on again.
Cause: Software error in radio.
Affected E46 with BMW Business radio (option 661)

vehicles: Manufacturing period: March 2001 to February 2002
Please refer to repair instructions ”Removing and installing / replacing radio receiver” RA 65
11 030.
Parts:
Within the scope of a visit to the workshop - Replace radio
Labour 3 FRUs
In case of order without additional repair operations - Replace radio
Labour 4 FRUs
Warranty type 1

Reimbursement is limited to 36 months/100,000 km and only possible until February 2005.

65 16 01 (784)
Volume of navigation instructions (option 609) too low
E39, E46, E53
Complaint: The volume of navigation instructions is too low in all radio operating modes, except off.
Cause: Radio software
Affected E39 with navigation system (option 609)

vehicles: Manufacturing period: from September 2001 until November 2001
E46 with navigation system (option 609)
Manufacturing period: from September 2001 until November 2001
E53 with navigation system (option 609)
Manufacturing period: from October 2001 until November 2001
Procedure: In case of customer complaint, increase the traffic news volume (TP volume) in the radio's
service menu to ”5”.
Procedure E46:
To access the service menu, switch on the radio and within the space of eight seconds, press the ”SEL”
button on the on-board monitor control panel and hold for approx. 8 seconds.
If this does not take you to the function required, proceed as follows:
Switch on the radio and within the space of eight seconds, press the ”SEL” button on the on-board
monitor control panel and hold for approx. 8 seconds. The display on the on-board monitor changes.
Press the ”SEL” button again to access the service menu.
Select the ”TP volume” menu with the station selector buttons.
Press button ”1” to set the ”TP volume” to be quieter and button ”2” to set the ”TP volume” to be louder.
Set the ”TP volume” with buttons ”2” to ”5”.
Switch the radio off to store the settings.
Procedure for E39, E53:
To access the service menu, switch on the radio and within the space of eight seconds, press the
”SELECT” button on the on-board monitor control panel and hold for approx. 8 seconds.
Select the ”TP volume” menu with the station selector buttons.
Press button ”1” to set the ”TP volume” to be quieter and button ”2” to set the ”TP volume” to be louder.
Set the ”TP volume” with buttons ”2” to ”5”.
Switch the radio off to store the settings.
Within the scope of a visit to the workshop, increase traffic news volume:
Labour 1 FRU
In case of order without additional repair operations - Increase traffic news volume:
Labour 2 FRUs
Warranty type 1
Warranty stage 1
Reimbursement is limited to 36 months/100,000 km and only possible until April 2005.
00 02 06 (296)

61 01 03 (952)
E46, R50/R53, E53, E38, E39, E36, Z3, Z4
control unit.
cause.
Important:
system.

Parts:
Warranty type 1

00653901/1299
259)
control unit.
be replaced.
higher.
N.B.:
Software reset
Battery reset
carried out.
diagnosis.”

M10 hexagon screw 52 10 8 211 438 4
M10 hexagon nut 61 61 8 215 610 4
00 65 39 01 00
Warranty type 1
Warranty level 1
65 13 00 (641)
must be observed.
a retrofit kit.
switch.

Attention!
Attention!
Key:
introduction
Enclosure 5.
Enclosure 6.
production
production
production
production
production
production
E60/E61 up to 08.05 1 1 1
E60/E61 From 09.05 2 2 1
E63 up to 08.05 1 1 1
E63 From 09.05 2 2 1
E64 up to 08.05 1 1
E64 From 09.05 2 2 1
production
production
production
E83 up to 08.04 1 1 1
E83 From 09.04 2 2 1
E84 from series 2 2
production
production
E87 From 03.05 2 2
E89 from series 2 2
production
E90/91/92/93 from series 2 2
production
R50/R53 up to 06.04 1 1 1
R50/53 From 07.04 2 2 1
R52 from series 2 2
production
production
production
production
production

Note:
E53 1
with option 230
E60/61/63/64 1
E65/66 1
E81/82/87/88 1
E83 1
E84 1
E85/86 1
E89 1
E90/91/92/93 1
MINI from R55 1
BMW F-Series 1
BMW i 1
2.
4.
vehicles 5.
warning 7
Note:
deactivated.
2004), R50,53 (to July 2004) OHNE
R52

limiter (EPC)
warning stickers)
00654001/1299
E46 CKD Mexico
by an accident.

N.B.:
a battery reset:
Software reset
the test functions.
Battery reset
battery.
be carried out.
00 65 40 01 00
Labour 3 FRUs
Warranty type 1
Warranty level 1
65 03 00 (573)
E46
memory.
vehicle side.
other.
Important:
control unit
side airbag
Shrink-fit hose 61 13 1 379 833 4






Warranty type 1


65 13 00 (641)
must be observed.
a retrofit kit.
switch.

Attention!
Attention!
Key:
introduction
Enclosure 5.
Enclosure 6.
production
production
production
production
production
production
E60/E61 up to 08.05 1 1 1
E60/E61 From 09.05 2 2 1
E63 up to 08.05 1 1 1
E63 From 09.05 2 2 1
E64 up to 08.05 1 1
E64 From 09.05 2 2 1
production
production
production
E83 up to 08.04 1 1 1
E83 From 09.04 2 2 1
E84 from series 2 2
production
production
E87 From 03.05 2 2
E89 from series 2 2
production
E90/91/92/93 from series 2 2
production
R50/R53 up to 06.04 1 1 1
R50/53 From 07.04 2 2 1
R52 from series 2 2
production
production
production
production
production

Note:
E53 1
with option 230
E60/61/63/64 1
E65/66 1
E81/82/87/88 1
E83 1
E84 1
E85/86 1
E89 1
E90/91/92/93 1
MINI from R55 1
BMW F-Series 1
BMW i 1
2.
4.
vehicles 5.
warning 7
Note:
deactivated.
2004), R50,53 (to July 2004) OHNE
R52

limiter (EPC)
warning stickers)
61 01 03 (952)
E46, R50/R53, E53, E38, E39, E36, Z3, Z4
control unit.
cause.
Important:
system.

Parts:
Warranty type 1

00653901/1299
259)
control unit.
be replaced.
higher.
N.B.:
Software reset
Battery reset
carried out.
diagnosis.”

M10 hexagon screw 52 10 8 211 438 4
M10 hexagon nut 61 61 8 215 610 4
00 65 39 01 00
Warranty type 1
Warranty level 1
65 13 00 (641)
must be observed.
a retrofit kit.
switch.

Attention!
Attention!
Key:
introduction
Enclosure 5.
Enclosure 6.
production
production
production
production
production
production
E60/E61 up to 08.05 1 1 1
E60/E61 From 09.05 2 2 1
E63 up to 08.05 1 1 1
E63 From 09.05 2 2 1
E64 up to 08.05 1 1
E64 From 09.05 2 2 1
production
production
production
E83 up to 08.04 1 1 1
E83 From 09.04 2 2 1
E84 from series 2 2
production
production
E87 From 03.05 2 2
E89 from series 2 2
production
E90/91/92/93 from series 2 2
production
R50/R53 up to 06.04 1 1 1
R50/53 From 07.04 2 2 1
R52 from series 2 2
production
production
production
production
production

Note:
E53 1
with option 230
E60/61/63/64 1
E65/66 1
E81/82/87/88 1
E83 1
E84 1
E85/86 1
E89 1
E90/91/92/93 1
MINI from R55 1
BMW F-Series 1
BMW i 1
2.
4.
vehicles 5.
warning 7
Note:
deactivated.
2004), R50,53 (to July 2004) OHNE
R52

limiter (EPC)
warning stickers)
00654001/1299
E46 CKD Mexico
by an accident.

N.B.:
a battery reset:
Software reset
the test functions.
Battery reset
battery.
be carried out.
00 65 40 01 00
Labour 3 FRUs
Warranty type 1
Warranty level 1
65 03 00 (573)
E46
memory.
vehicle side.
other.
Important:
control unit
side airbag
Shrink-fit hose 61 13 1 379 833 4






Warranty type 1


65 13 00 (641)
must be observed.
a retrofit kit.
switch.

Attention!
Attention!
Key:
introduction
Enclosure 5.
Enclosure 6.
production
production
production
production
production
production
E60/E61 up to 08.05 1 1 1
E60/E61 From 09.05 2 2 1
E63 up to 08.05 1 1 1
E63 From 09.05 2 2 1
E64 up to 08.05 1 1
E64 From 09.05 2 2 1
production
production
production
E83 up to 08.04 1 1 1
E83 From 09.04 2 2 1
E84 from series 2 2
production
production
E87 From 03.05 2 2
E89 from series 2 2
production
E90/91/92/93 from series 2 2
production
R50/R53 up to 06.04 1 1 1
R50/53 From 07.04 2 2 1
R52 from series 2 2
production
production
production
production
production

Note:
E53 1
with option 230
E60/61/63/64 1
E65/66 1
E81/82/87/88 1
E83 1
E84 1
E85/86 1
E89 1
E90/91/92/93 1
MINI from R55 1
BMW F-Series 1
BMW i 1
2.
4.
vehicles 5.
warning 7
Note:
deactivated.
2004), R50,53 (to July 2004) OHNE
R52

limiter (EPC)
warning stickers)
65 13 00 (641)
must be observed.
a retrofit kit.
switch.

Attention!
Attention!
Key:
introduction
Enclosure 5.
Enclosure 6.
production
production
production
production
production
production
E60/E61 up to 08.05 1 1 1
E60/E61 From 09.05 2 2 1
E63 up to 08.05 1 1 1
E63 From 09.05 2 2 1
E64 up to 08.05 1 1
E64 From 09.05 2 2 1
production
production
production
E83 up to 08.04 1 1 1
E83 From 09.04 2 2 1
E84 from series 2 2
production
production
E87 From 03.05 2 2
E89 from series 2 2
production
E90/91/92/93 from series 2 2
production
R50/R53 up to 06.04 1 1 1
R50/53 From 07.04 2 2 1
R52 from series 2 2
production
production
production
production
production

Note:
E53 1
with option 230
E60/61/63/64 1
E65/66 1
E81/82/87/88 1
E83 1
E84 1
E85/86 1
E89 1
E90/91/92/93 1
MINI from R55 1
BMW F-Series 1
BMW i 1
2.
4.
vehicles 5.
warning 7
Note:
deactivated.
2004), R50,53 (to July 2004) OHNE
R52

limiter (EPC)
warning stickers)
00 02 06 (296)

65 06 04 (126)
Master document for airbag/belt tensioner
All model series
Situation: The volume of information about the airbag/belt tensioner topic has greatly increased in
the past few years due to technical innovations. To simplify the targeted search for
information, this document contains a summary of all important information about the
handling of airbags/belt tensioners at the dealer's operation and can be accessed directly using hotspot.
Procedure: Search for a topic in the table below and select a document with hotspot.
1. Fault memory / airbag indicator light

"Airbag with seat occupancy detection" SI 65 04 96 (064)
Side airbag: Troubleshooting 05/06 (MRS3) or fault code SI 65 03 00 (573)
08/09 (MRS)"
"Airbag fault code 01/0D (MRS3): Driver's airbag" SI 65 07 00 (603)
2. Repair
"Repair of airbag systems that have been activated" SI 65 09 89 (126)
"Airbag, repair instructions for ignition circuits" SI 61 01 99 (397)
"Airbag: Repair instructions for the ignition circuit, belt SI 61 01 03 (952)
tensioner and/or side airbag"
"Airbag control unit replacement" SI 65 10 96 (129)
3. Deactivation / recoding
"Deactivated side airbags in the rear passenger SI 65 07 99 (442)
compartment"
"Check side airbag impact sensors and recode the SI 65 39 01 (000)
airbag control unit"
"Deactivation or reactivation of airbags / belt warning SI 65 13 00 (641)
sound"
84 02 00 (566)
Hands-free set: volume too low
E38, E39, E46 with communications package (option 628), car phone GSM
(option 629) or complete preparation for BMW Motorola mobile phone
(option 625)
Complaint: When a call is made through the hands-free set, the person at the other end hears the
person in the car with inadequate volume.
Cause: Fault cause 1:
A microphone with one of the following part numbers is not installed:
84 31 8 374 075 (with yellow label) or
84 31 8 380 319
These were introduced to series production in November 1997 and have been used retrospectively
whenever this complaint has been made (please refer to HLI 842212000).
Fault cause 2:
Felt strip between the microphone and the cover panel interferes with sound transmission.
Fault cause 3:
The distance between the driver and the microphone is too long and/or the driver is speaking too quietly.
Fault cause 4:
Excessive background noise. This could be caused by:
An air flow from the blower of the heater or air conditioner pointing directly upwards (towards the
microphone)
Fast speeds
Open windows.
Affected vehicles:E38, E39, E46 with communications package (option 628), car phone GSM (option 629)
or complete preparation for BMW Motorola mobile phone (option 625)
Manufacturing period: from March 1997
(from telephone generation Motorola Phase IV+)
Procedure: In case of customer complaint, the following procedures should be followed for all
corresponding complaints.
Remedy I:
Check part number of microphone, installation location and fitting of felt strip between cover panel and
microphone; correct as necessary.
1. Check microphone part number and replace microphone if necessary:
The part number is engraved on the cap of the microphone casing.
The part number must be either: 84 31 8 374 075 (with yellow label) or 84 31 8 380 319.
If the part number is anything other than these, the microphone must be replaced for the series
production status.
See also further below: "Install service variant of microphone".
2. Check installation location, correct as necessary.

The microphone has a directional characteristic which is directed towards the driver.
The arrow on the microphone casing must point in the direction of travel (forwards). If the arrow on the
microphone casing points in the opposite direction, the microphone must be turned through 180°.
3. Check fitting of felt strip and remove if necessary:

Remove the felt strip if it has been inserted loosely between the cover panel and the microphone.
The felt strip glued to the base of the microphone casing is not affected.
Remedy II:
Swap the installation locations of the microphone and of the sunroof (SHD) switch (only possible on E38,
E39 of manufacturing period up to August 1999).
This action shortens the distance between the driver and the microphone. On E38, E39 vehicles, this action
was incorporated into series production in August 1999.
1. Unclip both components (microphone and SHD switch) from their retainers and separate from the
connectors.
2. Remove the cover panel.
3. Route the cable connections to the other openings on the cover panel accordingly.
4. Snap the cover panel back into place.
5. Connect up the SHD switch and the microphone.
6. Clip the SHD switch and the microphone back into place.
Because of the installation situation, this action is not possible on the E46.
Remedy III:
Install service variant of microphone.
If the part number of the microphone is 84 31 8 374 075 (with yellow label) or 84 31 8 380 319 and the complaint
clearly relates to the volume, the microphone must be replaced with the service variant.
The service variant of the microphone has been optimised for volume but does not correspond to the
specifications of the telephone system in all points. In particular, distortions can occur when the volume is set
to loud, and vehicle background noise can also be picked up.
Remedy IV:
Explain the background to the customer:
1. Additional noises in the interior of the vehicle affect the transmission of speech through the microphone.
For this reason, it is important that the blower outlets are, if possible, not pointing directly upwards,
especially when a high blower speed is selected.
2. There is also an increased level of interior noise at high speeds, which will generally make communication
via the hands-free system more difficult.
3. On Motorola telephone systems, complaints of syllables being cut off (only sections of words are
understood, words are not ended, etc.) are not uncommon.
This is caused by the semi-duplex speech transmission. Speech transmission is only enabled in one
direction - the other direction is disabled. This is designed to prevent feedback within the vehicle. The
person speaking from outside the vehicle has priority. This is caused by the transmission concept and
cannot be rectified by any available actions. The level balance (switch point to enable/disable a
transmission direction) can however be influenced by:
1. The driver speaking clearly

Conducting the conversation in a disciplined manner
(not constantly interrupting)
The microphone volume transmitted (loud speech) also has a certain influence on the level balance in
favour of the driver.
Parts: Description Part number Qty.

Microphone 84 31 8 380 319 1
Microphone cover panel 51 44 8 250 108 1
(vehicles from 05/98)
Microphone 84 31 0 020 974 1
(service variant)
Remedy I (without microphone replacement)
Check installation location of microphone and correct as necessary; remove felt strip if
necessary.
Labour 1 FRU (E38, E39, E46 coupé/saloon/touring)
Remedy I
necessary; replace microphone.

Remedy I + II (without microphone replacement)
necessary; swap installation locations of SHD switch and microphone.
Labour 2 FRUs (E38, E39)

Remedy I + II
necessary; replace microphone; swap installation locations of SHD switch and microphone.

Remedy I + III
necessary; replace microphone with service variant.

Remedy I + II + III
necessary; swap installation locations of SHD switch and microphone; replace microphone with service variant.
For order without additional repair work:

Remedy I (without microphone replacement)
necessary.
Labour 3 FRUs (E38, E39, E46 coupé/saloon/touring)

Remedy I
necessary; replace microphone.

Remedy I + II (without microphone replacement)
necessary; swap installation locations of SHD switch and microphone.

Remedy I + II
Check installation location of microphone and correct as necessary; remove felt strip if necessary; replace
microphone; swap installation locations of SHD switch and microphone.

Remedy I + III
necessary; replace microphone with service variant.

Remedy I + II + III
necessary; swap installation locations of SHD switch and microphone; replace microphone with service variant.
Warranty type 1


36 months/100,000 km
84 13 01 (791)
Information on charging new batteries in cordless handset on GSM car phone
E38, E39, E46, E53 with GSM car phone with cordless handset (option 630)
Situation: New batteries in cordless handset (SBDH) must be formatted and charged before use.
Charging takes 10 hours. This can have a negative effect on the charge level of the
vehicle battery.
Affected vehicles: E38, E39, E46, E53 with GSM car phone with cordless handset (option 630)
Procedure: Ideally, the procedure should be as follows:
1. Connect a battery charger of a type approved by BMW to the vehicle battery.
2. Insert the batteries into the cordless handset, close the battery compartment cover and engage the
cordless handset in the eject box. This will start the formatting procedure.
3. Switch the ignition on and off again.
4. Leave the vehicle in this position for 10 hours.
5. Perform a function check on the cordless handset.
Formatted and charged batteries can be recognised by the dark battery pictograph in the display of the
handset.
If the process is interrupted during the 10 hours (e.g.Â by removing the cordless handset from the eject
box), the formatting process will be lengthened accordingly.
84 05 01 (700)
Nokia mobile phone: Telephone mute intermittently inactive
E38, E39, E46
Complaint: Intermittently, the telephone system does not switch the radio to mute. The radio remains
audible for a short time while a phone call is being made.
Cause: Software error in basis telephone interface (BIT I).
Affected E38, E39, E46 with complete basic fittings for BMW Nokia mobile phone (option 627) or
vehicles: basic equipment for installation of mobile phone (option 640) and retrofit option 627.
Manufacturing period: September 1999 to May 2000
Procedure: In case of customer complaint, check the basic telephone interface (BIT I) and replace
if necessary
1. Remove the interface.
Please refer to Repair Instructions ”Removing and installing / replacing hands-free charging electronics”,
RA 84 21 530.
2. Check the part number of the interface. This is printed on the label of the interface.
If the part number is 84 21 6 907 315:
Replace the interface.
If the part number is 84 21 6 916 909:

The interface is OK.

Mobile phone interface for 84 21 6 916 909 1
D-network
Within the scope of a visit to the workshop - Check interface (BIT I):
Labour 5 FRUs (E38 without on-board monitor/navigation system)

2 FRUs (E39 saloon)
4 FRUs (E46 saloon, coupé)
4 FRUs (E46 touring without on-board monitor/navigation system)
Labour 9 FRUs (E38 with on-board monitor/navigation system)

16 FRUs (E46 touring with on-board monitor/navigation system)
Check and replace interface (BIT I):

2 FRUs (E39 saloon)
Job number 0 53 503

In case of order without additional repair operations - Check interface (BIT I):

4 FRUs (E39 saloon)

In case of order without additional repair operations - Check interface and replace
interface (BIT I):

4 FRUs (E39 saloon)

Warranty type 1 (option 627 or option 640 ordered from factory)
2 (original BMW retrofit parts set, option 627)
Reimbursement is limited to 36 months/100,000 km and only possible until May 2003.

84 01 02 (809)
Siemens fixed telephone: Various fault patterns
E38, E39, E46, E53 with GSM car phone with cordless handset (option 630)
Complaint: The following problems can occur:
1. Problems when transmitting DTMF tones via the on-board monitor, multi-information display or cordless
handset (e.g. select mailbox, 0800 provider).
2. The telephone can no longer be operated after ending a telephone connection. The cordless handset
display reads ”Please wait”. The green LED in the on-board monitor may remain on.
3. SIM cards with deactivated PIN are not recognized. The handset display alternately reads ”Please wait”
and ”Please insert card”.
4. A telematics SMS with * is displayed in the cordless handset and cannot be cleared.
Even after restarting the telephone system, it is still not possible to clear the SMS.
5. The engaged tone cannot be heard in hands-free mode if the number being called is not available.
Cause: Software error in the installed transceiver
Affected E38, E39, E46, E53 with GSM car phone with cordless handset (option 630) or basic fittings
vehicles: for telephone installation (option 640) and retrofitted GSM car phone with cordless
handset (option 630)
E38, E39, E46, E53: from October 2000 until December 2001
Procedure: In case of customer complaint, check the transceiver (BIT II) and if necessary, replace
it together with the cordless handset.
1. Remove transceiver.
Please refer to repair instructions ”Removing and installing transceiver”, RA 84 11 620.
2. Check software status of transceiver. This is printed on the label on the transceiver (see illustration 1).
Figure 1
If the software is of an earlier version than C01.53:
Replace the transceiver and the cordless handset.

Please refer to repair instructions ”Replacing transceiver”,
RA 84 11 622.
Continue with point 3.
If the software is of version C01.53 or later:
If problems occur, the exchange package transceiver + cordless handset is not to be replaced. Only the
defective component (transceiver or cordless handset) should be replaced individually. Place a warranty
claim for this troubleshooting using a standard defect code.
3. Insert the batteries and the battery compartment lid from the old handset in the new handset.
4. Match the cordless handset to the transceiver with the DIS tester.
5. Format the batteries in the cordless handset (please refer to Service Information bulletin SI 84 13 01
(791) ”Notes on charging new batteries in the GSM car phone cordless handset”
6. Perform a function check on telephone system.
7. For reasons of quality, the complaint corresponding to the fault description must be entered in the
remarks field on the warranty claim (please refer to the section headed ”Complaint”).
For Germany:
Return the removed transceiver together with the cordless handset (without batteries and battery
compartment lid) as quickly as possible to BMW as part number 84 11 6 924 824.
Only use one damaged parts tag and only submit one warranty claim.
Parts:
Exchange transceiver / 84 11 6 924 824 1
handset
defect code catalogue, but has been included in the system, thus
Within the scope of a visit to the workshop - Check transceiver:
Labour 5 FRUs (E38 without on-board monitor / navigation system)

4 FRUs (E39 saloon)
5 FRUs (E53)
4 FRUs (E46 touring without CD changer or navigation system)

16 FRUs (E46 touring with CD changer or navigation system)
Check transceiver, replace transceiver and cordless handset:

6 FRUs (E39 saloon)
7 FRUs (E53)

In case of order without additional repair operations - Check transceiver:

5 FRUs (E39 saloon)
6 FRUs (E53)
9 FRUs (E46 compact, convertible)

In case of order without additional repair operations - Check transceiver, replace
transceiver and cordless handset:

7 FRUs (E39 saloon)
8 FRUs (E53)
11 FRUs (E46 compact, convertible)

Warranty type 1 (option 630 or option 640 ordered ex-works)
2 (Original BMW option 630 retrofit parts kit)

41 01 08 (452)
All
29 2 148 332.
41 01 08 (452)
All
29 2 148 332.
00 00 Extract from BMW Group Standard GS 90003-2
Tightening Torques
Type Thread Tightening Torque
specifications
If there are no cross-references to
tightening torques in the repair
instructions, the extracts based on
BMW Group Standard GS 90003-2
must be observed.
A distinction is made between

screws / bolts / nuts with surface
colour / (surface coating) yellow
(ZN) and silver (ZNS)
The maximum tightening torques
are:
Surface colour yellow (ZN):
Applicable only to set screws with
metric coarse and fine threads to
DIN 13-28 and nuts with nut height
of 0.8 x d to DIN 934 and
exclusively for a total µ = 0.125
(screws/bolts phosphatised, nuts
untreated or galvanized. Lubricated
condition: both unlubricated and
oiled).
Surface colour silver (ZNS):

Applicable only to set screws with
metric coarse and fine threads to
DIN 13-28 and nuts with nut height
of 0.8 x d to DIN 934 and
exclusively for a µ range = 0.09 0.15
(screws/bolts cadmium-plated, nuts
untreated or galvanized. Lubricated
condition: both unlubricated and
oiled).
The values specified in the table
apply to a screw/screw connection
in accordance with the above-
mentioned conditions.
Not applicable when a different
thread surface or lubrication status
is used or in the case of deviating
nut height.
Also not applicable to screws/bolts
reduced shafts, to self-locking
screw/bolt connections and to
screwing/bolting parts made of
different materials.
Caution!
It is essential to adhere to the
prescribed tightening torques in
order to carry out a correct and
proper repair. This presupposes
that the torque wrenches required
for this purpose are subject to
regular testing.
Permitted tolerance of calibrated
torque wrenches is ± 4 % from the
scale value.
Approved torque wrenches and
torque testers are featured in the
Workshop Equipment Planning
Catalogue.
00 00 M10 and M10 x 1 - maximum tightening torques acc. to BMW GS 90003-2
Tightening Torques
specification
Scope of applicability of tightening Surface colour
torques, / (surface
coating)
refer to excerpt from company
standard BMW GS 90003-2
M10 thread yellow (ZN) M10 8.8 47 Nm
silver (ZNS) M10 8.8 38 Nm

yellow (ZN) M10 10.9 66 Nm
M10x1 thread yellow (ZN) M10 x 1 8.8 54 Nm
silver (ZNS) M10 x 1 8.8 41 Nm

yellow (ZN) M10 x 1 10.9 75 Nm
00 00 M12 and M12x1.5 - maximum tightening torques acc. to BMW GS 90003-2
Tightening Torques
specification
torques, / (surface
coating)

M12x1.5 thread yellow (ZN) M12 x 1.5 8.8 87 Nm
silver (ZNS) M12 x 1.5 8.8 68 Nm

yellow (ZN) M12 x 1.5 123 Nm
10.9
silver (ZNS) M12 x 1.5 100 Nm
10.9
12.9
12.9
Tightening Torques
specification
torques, / (surface
coating)

silver (ZNS) M14 x 1.5 8.8 110 Nm

10.9
10.9
12.9
12.9
Tightening Torques
specification
torques, / (surface
coating)

silver (ZNS) M16 x 1.5 8.8 170 Nm

10.9
10.9
12.9
12.9
Tightening Torques
specification
torques, / (surface
coating)

silver (ZNS) M18 x 1.5 8.8 245 Nm

10.9
10.9
12.9
12.9
00 00 M4 and M5 - maximum tightening torques acc. to BMW GS 90003-2
Tightening Torques
specification
torques, / (surface
coating)


00 00 M6 and M7 - maximum tightening torques acc. to BMW GS 90003-2
Tightening Torques
specification
torques, / (surface
coating)


00 00 M8 and M8 x 1 - maximum tightening torques acc. to BMW GS 90003-2
Tightening Torques
specification
torques, / (surface
coating)

M8x1 thread yellow (ZN) M8 x 1 8.8 26 Nm

0 operating fluid overview
Expendable materials
Fitting aid 250 ml, 83192405829

(Circo Light; lubricant) Bottle
Lubricating grease Renolit CX-SP 1 100 g, 83192183737

Tube
Lubricating grease Klübersynth LF 44-22 45 g, 83230396713

Tube
Ball bearing grease 100 g, 81229407174

Tube
Lubricating oil 4 UH 1 - 460 N 100 ml, 83230306232

Bottle
Wheel bearing grease UNIREX N3 400 ml, 83192160349

Cartridge
Lubricating grease MI-Setral-43 N 50 g, 83232152082

Tube
Lubricating grease GKY H-15 100 g, 83232179705

Bag
Lubricating grease One Lube Improved 110 g, 83232179708

Bag
Silicone spray 400 ml, 83192208609

Spray can
Universal lubricant spray 250 ml, 81229407711

Spray can
Adhesive lubricant 250 ml, 81229407629
Spray can
Door brake lubricating grease 400 ml, 83230301796

Spray can
Lubricating material Optimoly Paste TA 400 ml, 83239407817

Spray can
Quietsch-Ex 250 ml, 83230420633

Spray can
Lubricating grease Klüberplex BE 11-462 400 ml, 83220397761

Spray can
Fluropan T20 spray with PTFE 400 ml, 83230154884

Spray can
Lubricating grease Renolit CX-CVM 1 100 g, 83192286016

Bag
Lubricating grease Renolit CX-CVL 1 100 g, 83192286017

Bag
Lubricating grease Renolit CX-TP 1 100 g, 83192286018

Bag
Paste MP 3 100 g, 07559062476

Tube
Active rust film remover 500 ml, 83192211267

Spray can
Contact-protection greaseKF1 50 g, 83192295229

Tube
Special lubricant KRYTOX 30 ml, 83199408523
Bottle
Paints and colours
BMW sound insulating paint 1 50 g, 83192414997

Spray
Paints and colours
Sound insulating paint Berucoat AK 978 100 ml, 83192358109

Spray can
Sealing compound
Silicone sealant Drei Bond 1207 310 ml, 81229407439

Cartridge
Sealing compound
Surface sealant Loctite 574 50 ml, 81229407301

Bottle
Sealing compound

Cartridge
Sealing compound
Surface sealant 2054/2 12 g, 83190412375

Cartridge
Sealing compound
Special activator type 5900 10 ml, 83190412376

Bottle
Adhesive
Adhesive anaerobic Drei Bond 1385 50 g, 83190417376

Bottle
Adhesive
Adhesive Loctite 577 50 ml, 33112328736

Bottle
Sealing compound

Cartridge
Sealing compound
Loctite 5460 liquid sealing compound 50 ml, 83192420102

Cartridge
Adhesive
Screw lock Loctite Stick 268, high strength 19 g, 83190441108

Pin
Adhesive
Screw lock Loctite 270, high strength 10 ml, 83192210337

Bottle
Adhesive
Screw lock Loctite 243, medium strength 10 ml, 83192210339

Bottle
Adhesive

Bottle
Adhesive

Bottle
Adhesive
Profile rubber adhesive

No longer available from BMW.
Adhesive

Bottle
Adhesive

Bottle
Adhesive
Adhesive 2K Loctite 3450 25 ml, 51252313730

Bottle
Adhesive
BMW Glue Pen 10 g, 81222358167

Pin
Adhesive
SuperglueS1 20 g, 81222351255
Bottle
Adhesive
SuperglueS2 20 g, 81222351257
Bottle
Adhesive
SuperglueS3 3 g, 81222351258
Bottle
Cooling spray 400 ml, 83199407762

Spray can
Odour remover 100 ml, 83192233353

Spray can
Rust film remover Professional 5 l, 83192166998

Canister
200 l, 83120396936
Barrel
1000 l, 83120396937
Barrel
Rust film remover Rv26H 500 ml, 83120414441

Spray bottle
Preservative remover 60 l, 83190422208

Canister
Universal cleaner exterior 10 l, 83192153221

Canister
25 l, 83192154648
Canister
Stain remover 1 l, 83119407816

Can
Adhesive remover 1 l, 83110009712

Can
Universal cleaner interior 20 l, 83192154638

Canister
Care product
Wheel rim brushes 1x , 83192298237
Set
Sealing compound
Loctite 171000 primer 4 ml, 83197515683

Bottle
Overview of consumables (Electronic Parts Catalogue)
Sealing compound

Cartridge
Sealing compound
Sealant Dow Corning 35 ml, 07580397777

Tube
Adhesive

Bottle
Engine and cold cleaner 1 l, 83192360950

Spray bottle
10 l, 83192361705
Canister
Leak detection spray 400 ml, 83199407861

Spray can
Contact spray 250 ml, 83222405599

Spray can
Powder spray 300 ml, 83192358648

Spray can
Vacuum pump oil 1 l, 83192232502

Bottle
Lubricants PF1 50 g, 83230309627

Lubricants PF1 50 g, 83230309627
Pin
Injector lubricating grease 50 g, 83230441070

Can
Adhesive
Screw lock Loctite Stick 248, medium strength 19 g, 83192359746

Pin
Universal cleaner 20 l, 83192360981

Canister
1100 Overview of tightening torques
Engine fixture to engine support arm
Hexagon screws from special tool set Tightening torque 105Nm
Engine support arm on the assembly stand
M14 x 95 Tightening torque 130Nm
Standard screw connection 4 Nm
Oval-head screw Tightening torque 4Nm
Standard screw connection M10
M10 38Nm
M5 5Nm
M6 8Nm
M7 13Nm
M8 Tightening torque 19Nm
Standard screw connection hose clamp 5

Hose clamp L12 - L15 Tightening torque 1,25Nm
11 11 Engine block
Tightening Torques
Type Thread Tightening specification Torque
1AZ Main bearing screws M10 / M20 / M10 Replace, wash and oil 60 Nm
M30 screws
M21 M10 Replace, wash and oil 65 Nm
screws
S38 / S14 / M40 M10 Replace, wash and oil
/ M42 / M43 / screws
M43TU / M44 /
M50 / M41 /
M51 / S50 / S50
US
Jointing torque 20 Nm
Torque angle 50 °
M47 / M57 M10 Replace, wash and oil
screws
Torque angle 70 °
M47TU / M10 Replace, wash and oil
M57TU screws
Torque angle 90 °
M67 M12 Replace, wash and oil
screws
Torque angle 200 °
S54 M10 Replace, wash and oil
screws
Torque angle 50 °
2AZ Main bearing screws M70 / S70 / M10 Replace screws
M73 Do not wash off screw
coating
Torque angle 70 °
M60 / M62 M10/M11 Replace screws
Do not wash off screw
coating
M10/M11 Jointing torque 20 Nm
M10 Torque angle 70 °
M54 / M56 / M10 Replace, wash and oil
M52TU / M52 / screws
with aluminum
engine block
Torque angle 70 °
S52 / M52 / with M10 Replace, wash and oil
cast iron screws
engine block
Torque angle 50 °
11 11 Engine block
Tightening Torques
specification
3AZ Taper screw mount on main
bearing
Screws and spacer bolts M60 / M62 / M8 Replace screws

M70 / S70 /
M73 / S62
Torque angle 45 °
N62 / N62TU / M8 34 Nm
N73
Threaded support sleeves M70 / M60 / 10 Nm
M62 / S70 /
M73 / S62
N62 / N62TU / 6 Nm
N73
4AZ Struts/bracing shell M67 M10.9 66 Nm
M10 43 Nm
M8 22 Nm
5AZ Drain plug for coolant in engine M14 x 1.5 25 Nm
block
6AZ Main oil gallery seal plugs M16 x 1.5 34 Nm
M18x1.5 40 Nm
N62 / N62TU / M18x1.5 Insert screw with Loctite 25 Nm
N73
N40 / N42 / M16x1.5 36 Nm
N45 / N46
Main oil gallery, rear (seal plugs with M62 / S62 M18x1 10 Nm
control valve)
7AZ Oil spray nozzle on engine M6 10 Nm

block
Oil spray nozzle screwed into M73 M8x1 5 Nm

bearing seat (coat thread with
Loctite 243)
Oil spray nozzle to engine block M8x1 12 Nm

(banjo bolt)
8AZ Pressure holding valve to S54 / B32 20 Nm

crankcase (1bar)
11 31 Engine block
Tightening Torques
1AZ Oil spray line to sliding rail N62 M8x50 22 Nm
assembly
11 12 Cylinder head
Tightening Torques
specifications
6AZ Cylinder head bolts S50 / S54 M11 Replace, wash and oil
screws
Angle of rotation 90 °
7AZ Cylinder head bolts M47 / M47TU / M12x1.5 Replace, wash and oil
M57 / M57TU screws
Loosen all screws by half
a turn
M67 M10/M12x1.5 Replace, wash and oil
screws
Loosen all screws by half
a turn
11 12 Cylinder head with lid
Tightening Torques
specifications
11AZ Cylinder head cover alle M6 10 Nm
alle M7 15 Nm
M21 M8 15 Nm
12AZ Oil separator to cylinder head M21 M8 17 Nm
cover
13AZ Timing case to cylinder head alle M7 15 Nm
alle M8 20 Nm
14AZ Screw plug for oil duct (micro- M47 / M57 M12x1.5 20 Nm
encapsulated)
15AZ Bleeder screw to cylinder M67 M10x1 2 Nm

head (coolant)
1112 Overview of Technical Data
Cross deviation from flatness

max. 0,05 mm
Longitudinal deviation from flatness

max. 0,10 mm
Flange to assembly stand
M14X30 Tightening torque 135Nm

11 13 Oil Pan
Tightening Torques
specification
1AZ Oil drain plug M12 x 1.5 25 Nm
M18 x 1.5 35 Nm
M22 x 1.5 60 Nm
2AZ Oil pan on engine block M6 8.8 10 Nm
M6 10.9 12 Nm
N40 / N42 / M8 8.8 Replace screws 30 Nm
N45 / N46
M8 8.8 22 Nm
Oil sump, lower section to upper M6 8.8 10 Nm
section
N62TU M8 24 Nm
M8 8.8 22 Nm
Oil sump bottom section to top M6 10.9 Replace screws 12 Nm
section with microencapsulated
screws
Oil sump upper section to N62TU M6 10 Nm

crankcase
N62TU M8 20 Nm
11 14 Case Covers
Tightening Torques
specification
1AZ Timing case and timing case M6 10 Nm
cover top and bottom
M7 15 Nm
M8 22 Nm
M10 47 Nm
2AZ End cover, front/rear, to engine M6 10 Nm
block
M8 22 Nm
3AZ Bearing pin to timing case M51 / M41 / M42x1.5 65 Nm
cover M47
4AZ Screw plug or connection piece M51 / M41 / M20x1.5 30 Nm

to timing case cover M47
Screw plug to timing case
cover
Screw plug to timing case cover M57 / M47TU / M30x1 70 Nm

M57TU
Screw plug to timing case cover M57 / M47TU M40x1.5 30 Nm
5AZ End cover, top/rear (water N62TU / N73 M6 10 Nm

jacket), to engine block
6AZ Lower timing case cover to N62TU M8 20 Nm

crankcase
7AZ Upper timing case to cylinder N62TU M6 10 Nm

head
8AZ End cover, rear, to crankcase N62TU M6 10 Nm

11 24 Connecting Rods and Bearings
Tightening Torques
1AZ Connecting rod bolts M10 / M30 Replace, wash and oil 55 Nm
screws
M20 / M21 / Replace, wash and oil
M40 / M41 / screws
M42 / M43 /
M43TU / M44 /
M47 / M47TU /
M50 / M51 /
M52 / M52TU /
M54 / M56 /
M57 / M57TU /
S52 / S50 US /
M70 / S70 /
M73 / N40 /
N42 / N45 / N46
/ N62 / N73 /
N62S / N62TU
Application torque 5 Nm
Torque angle 70 °
M60 / M62 Replace, wash and oil
screws
Torque angle 80 °
M67 Replace screws, do not
wash off screw coating
Torque angle 85 °
11 21 Crankshaft and Bearings
Tightening Torques
1AZ Increment wheel on crankshaft S54 M5 10.9 Replace screws
Jointing torque 5.0 Nm

Torque angle 45 Â°
Increment wheel on crankshaft M5 10.9 Replace screws 13 Nm
Increment wheel on crankshaft M5 8.8 Replace screws 5.5 Nm

11 11 Engine block
Tightening Torques
M30 screws
screws
M43TU / M44 /
M50 / M41 /
M51 / S50 / S50
US
Torque angle 50 °
screws
Torque angle 70 °
M57TU screws
Torque angle 90 °
screws
Torque angle 200 °
screws
Torque angle 50 °
coating
Torque angle 70 °
coating
with aluminum
engine block
Torque angle 70 °
cast iron screws
engine block
Torque angle 50 °
11 11 Engine block
Tightening Torques
specification
bearing

M70 / S70 /
M73 / S62
Torque angle 45 °
N62 / N62TU / M8 34 Nm
N73
M62 / S70 /
M73 / S62
N62 / N62TU / 6 Nm
N73
M10 43 Nm
M8 22 Nm
block
M18x1.5 40 Nm
N73
N40 / N42 / M16x1.5 36 Nm
N45 / N46
control valve)

block

Loctite 243)

(banjo bolt)

crankcase (1bar)
11 31 Engine block
Tightening Torques
assembly
11 22 Flywheel
Tightening Torques
specifications
1AZ Flywheel to crankshaft
Manual gearbox flywheel to S62 / M60/1 / Do not install with screw 105 Nm
crankshaft. M60/2 / M62 locking agent.
/S54 The bolts are integral
components on the
flywheel.
Threads on bolts oiled.
Manual gearbox flywheel to M40 / M42 / Replace screws 120 Nm
crankshaft. M43 / M43TU /
M44 / M70 /
S70 / M73 /
M57TU
M57 / M47 / Replace screws 105 Nm
M47TU / M52 /
M54
Automatic flywheel to crankshaft. N62 / N62TU / Replace screws 105 Nm
N73
Automatic flywheel to crankshaft. M57 / M57TU / Replace screws 121 Nm
M47 / M47TU /
M67 / M67TU /
M52 / M54
Manual gearbox flywheel to N62 Do not install with screw 120 Nm
crankshaft. locking agent.
The bolts are integral
components on the
flywheel.
Threads on bolts oiled.
11 23 Vibration Damper
Tightening Torques
1AZ Vee belt pulley on crankshaft M10 Replace nut 190 Nm
2AZ Vibration damper / hub to M20 / M21 / M18 x 1.5 Replace screws 410 Nm
crankshaft M50 / M52 /
M52TU / S50
US / S52 / M54
/ M56
M30 / S14 / M24 x 1.5 Replace nut 440 Nm
S38 / B35
M41 / M47 / M18 x 1.5 Replace screw
M47TU / M51 /
M60 / M62
Torque angle 60 °
Torque angle 60 °
Torque angle 30 °
N62 / N62TU / M18 x 1.5 Replace screw
N73 Grease head
Torque angle 60 °
Torque angle 60 °
Torque angle 60 °
M70 / S70 / M18 x 1.5 Replace screw
M73
Torque angle 60 °
Torque angle 60 °
M57 / M57TU / M10 Replace screws
M67 / M67TU
Torque angle 60 °
Torque angle 60 °
11 24 Connecting Rods and Bearings
Tightening Torques
1AZ Connecting rod bolts M10 / M30 Replace, wash and oil 55 Nm
screws
M20 / M21 / Replace, wash and oil
M40 / M41 / screws
M42 / M43 /
M43TU / M44 /
M47 / M47TU /
M50 / M51 /
M52 / M52TU /
M54 / M56 /
M57 / M57TU /
S52 / S50 US /
M70 / S70 /
M73 / N40 /
N42 / N45 / N46
/ N62 / N73 /
N62S / N62TU
Torque angle 70 °
M60 / M62 Replace, wash and oil
screws
Torque angle 80 °
M67 Replace screws, do not
wash off screw coating
Torque angle 85 °
11 11 Engine block
Tightening Torques
M30 screws
screws
M43TU / M44 /
M50 / M41 /
M51 / S50 / S50
US
Torque angle 50 °
screws
Torque angle 70 °
M57TU screws
Torque angle 90 °
screws
Torque angle 200 °
screws
Torque angle 50 °
coating
Torque angle 70 °
coating
with aluminum
engine block
Torque angle 70 °
cast iron screws
engine block
Torque angle 50 °
11 11 Engine block
Tightening Torques
specification
bearing

M70 / S70 /
M73 / S62
Torque angle 45 °
N62 / N62TU / M8 34 Nm
N73
M62 / S70 /
M73 / S62
N62 / N62TU / 6 Nm
N73
M10 43 Nm
M8 22 Nm
block
M18x1.5 40 Nm
N73
N40 / N42 / M16x1.5 36 Nm
N45 / N46
control valve)

block

Loctite 243)

(banjo bolt)

crankcase (1bar)
11 31 Engine block
Tightening Torques
assembly
11 28 V-ribbed belt with Tension and Deflection Element
Tightening Torques
1AZ Idler lever to alternator bracket M43 M10 10.9 Replace screw 90 Nm
2AZ Plug for bearing pin M51 / M41 / M35 x 3 20 Nm

M47
3AZ Belt tensioner to engine block N40 / N42 / N45 M10 40 Nm
/ N46
4AZ Belt tensioner to engine block N62TU M10 42 Nm
SWZ2249117
Screw M6 Tightening torque 10Nm

11 31 Camshaft
Tightening Torques
1AZ Camshaft bearing cap M6 10 Nm
M7 14 Nm
M7- 8.8 15 Nm
M8 20 Nm
2AZ Sprocket to camshaft M20 / M21 / M10 65 Nm
M40
3AZ Sprocket to camshaft flange M60 / M62 M6 15 Nm
M6 10 Nm
M50 / M52 / M7
M52TU / M54 /
M56 / S52 /
S50 US / M50 /
VANOS
M7 15 Nm
4AZ Sprocket to camshaft M51 / M41 / M12 x 1.5 Replace screws
M47 / M57
Torque angle 35 째
M47TU / M12 x 1.5 Replace screws
M57TU
Torque angle 50 째
M67 M12 x 1.5 Replace screws
Torque angle 90 째
5AZ Toothed shaft to inlet camshaft M52 / S52 / M14 x 1.5
S50 US / M50 /
VANOS
Torque angle 60 째
11 31 Camshaft
Tightening Torques
6AZ Flange to camshaft M30 145 Nm
7AZ Screw plug for chain tensioner M50 / S50 US / M22 x 1.5 50 Nm
S62
M22 x 1.5 40 Nm
8AZ Cylinder for chain tensioner M67 M22 x 1.5 45 Nm
plunger
N40 / N42 / N45 M22 x 1.5 65 Nm
/ N46 / N62 /
N62TU / N73
M50 / M52 / M26 x 1.5 70 Nm
M52TU / M54 /
M56 / S52 /
S50 US
M26 x 1.5 50 Nm
9AZ Bearing flange on engine block M60 M6 13 Nm
10AZ Reversing rail on engine block M62 / S62 M6 /M7 14 Nm
11AZ Screw-in pin on camshaft M7 20 Nm
Nut on screw-in pin M6 10 Nm
12AZ Bearing pin for sliding and M41 / M47 / M16 x 1.5 20 Nm
tensioning rails M47TU / M51 /
M57 / M57TU
M67 M16 x 1.5 26 Nm
13AZ Signal disk to camshaft S62 / S54 M16 x 1.5 50 Nm
14AZ Sensor gear to camshaft N62 / N62TU / M14 x 1.5 30 Nm

N73
Preload timing chain
Tightening torque 0,6Nm
11 41 Oil pump with strainer and motor
Tightening Torques
specifications
1AZ Screw plug for pressure limiting M10 / M30 40 Nm
valve
M20 30 Nm
2AZ Oil pump to crankcase N62 / N62TU / M8 10.9 34 Nm
N73
M54 / S54 / M8 21 Nm
S62
3AZ Oil pump cover M6 10 Nm
4AZ Sprocket to oil pump M6 10 Nm
N40 / N42 / M10 x 1 30 Nm

N45 / N46
M54 / S54 / M10 x 1 Left-hand threads. 25 Nm
S62
N62 / N62TU M10 45 Nm
M57TU M8 x 35 Jointing torque 5 Nm
Angle of rotation 90 Â°
5AZ Oil pump to counterbalance M47TU M6 10.9 14 Nm
shaft housing
M47TU M7 10.9 25 Nm
11-30 42 Oil Filter and Lines
Tightening Torques
specifications
1AZ Easy-change filter (disposable Nm
cartridges)
(tightening torque by hand
according to specification on
easy-change filter)
2AZ Full-flow oil filter (lid) M8 22 Nm
M10 33 Nm
M12 33 Nm
Screw cap 25 Nm
3AZ Oil filter housing and lines to M8 22 Nm

crankcase
M20 x 1.5 40 Nm
11 42 Oil Filter and Pipes
Tightening Torques
4AZ Oil filter drain plug M21 / S38 Hollow bolt 20 Nm
M21 Full length 10 Nm

screw in
aluminum
M21 Full length 23 Nm
screw in
threaded
insert
5AZ Oil drain line to oil filter and M60/1 / M60/2 / Banjo bolt 30 Nm
upper oil sump section M62 / M70 / M14x1.5
S70 / M73 /
S62
6AZ Oil line to bearing points and M6 10 Nm
camshaft lubrication
7AZ Oil line for camshaft lubrication Banjo bolt 10 Nm

on cylinder head M8x1
N40 / N42 / Banjo bolt 10 Nm

N45 / N46 M7x1
M5 5 Nm
8AZ Oil drain line from oil separator E53 / M62 Banjo bolt 25 Nm
to upper oil sump section M12 x 1.5
11 42 Oil Filter and Pipes
Tightening Torques
specification
8AZ Oil cooler oil pipes to oil filter M8 22 Nm
housing
9AZ Oil pipes to turbocharger M8 22 Nm
10AZ Oil lines from turbocharger to M16 x 1.5 40 Nm

engine block
Hollow bolt
11AZ Oil supply pipe to turbocharger
Hollow bolt 25 Nm
Coupling nut 30 Nm
Oil return line to turbocharger and M47TU / M57 / 3 Nm

cylinder crankcase (hose clamp) M57TU / M67
11 51 Water Pump and Drive
Tightening Torques
1AZ Water pump to crankcase M6 10 Nm
M7 15 Nm
M8 22 Nm
2AZ Water pump to power steering N40 / N42 / M8 10.9 32 Nm
pump N45 / N46
11 52 Fan
Tightening Torques
1AZ Fan clutch on water pump All 40 Nm
Coupling nut (left-hand
threads)
M54 45 Nm
2AZ Fan to fan clutch All 10 Nm
11 61 Intake manifold
Tightening Torques
specifications
1AZ Intake manifold to cylinder head alle M8 22 Nm
alle M7 15 Nm
alle M6 10 Nm
2AZ Sound absorption cover to M60/1 / M60/2 / M6 8 Nm
holder M62
3AZ Throttle valve to intake N73 M6x60/ 8 Nm

manifold M6x80
11 62 Exhaust manifold
Tightening Torques
specifications
1AZ Exhaust manifold to cylinder head All M6 Replace nuts 10 Nm
Coat screw connections with CRC copper
paste
M50 / M52 / M7 Replace nuts 20 Nm

M52TU /
M54 / M56 /
S52 /
S50US
All / others M7 Replace nuts 15 Nm
M10 M8 Insert upper stud
bolt row with screw
lock
23 Nm
M21 M8 12 Nm
Replace nuts
Retighten after
2000Â km
Undo nuts by a 1/4
turn
12 Nm
M41 / M47 / M8 Replace nuts 20 Nm
M47TU /
M51 / M57 /
M57TU
11 65 Turbocharger and Control
Tightening Torques
specification
1AZ Turbocharger to exhaust M21 M10 25 Nm
manifold
M30 45 Nm
M41 / M51 / M10 50 Nm
M47 / M47TU /
M57 / M47T2 /
M57TU / M67
2AZ Bypass valve to flow section M30 M8 25 Nm
3AZ Ring nut to exhaust manifold M30 220 Nm
4AZ Screws to bypass valve M30 M6 10 Nm
5AZ Flow section to exhaust M30 M8 22 Nm

manifold
6AZ Flange for oil return to M30 M8 22 Nm

turbocharger
7AZ Oil feed to turbocharger and M51 / M41 / 25 Nm

engine block / cylinder head M47 / M47TU /
(banjo bolt) M47T2 / M57 /
M57TU / M67
8AZ Screw plug to oil return M30 M16 45 Nm
9AZ Control line to bypass valve / M30 30 Nm

turbocharger
10AZ Hose clamps for charge air M47 / M47TU / 6 Nm

hoses M57 / M57TU /
M67
11 66 Vacuum pump
Tightening Torques
1AZ Vacuum pump on cylinder M21 M6 10 Nm
head
M51 / M41 M8 22 Nm
M51 / M41 M9 Microencapsulated 22 Nm
Replace screw
M47 / M47TU / M8 22 Nm
M57 / M57TU /
M67
11 71 Exhaust gas recirculation (EGR)
Tightening Torques
1AZ Exhaust pipe to EGR M21 / M51 / 8 Nm
valve/EGR cooler M41 / M47 /
M47TU / M57 /
M57TU / M67
11 78 Emissions-control, Lambda oxygen sensor
Tightening Torques
1AZ Oxygen control sensor; All M18 x 1.5 50 Nm
oxygen monitor sensor
11 14 Case Covers
Tightening Torques
specification
1AZ Timing case and timing case M6 10 Nm
cover top and bottom
M7 15 Nm
M8 22 Nm
M10 47 Nm
2AZ End cover, front/rear, to engine M6 10 Nm
block
M8 22 Nm
3AZ Bearing pin to timing case M51 / M41 / M42x1.5 65 Nm
cover M47
4AZ Screw plug or connection piece M51 / M41 / M20x1.5 30 Nm

to timing case cover M47
Screw plug to timing case
cover
Screw plug to timing case cover M57 / M47TU / M30x1 70 Nm

M57TU
Screw plug to timing case cover M57 / M47TU M40x1.5 30 Nm
5AZ End cover, top/rear (water N62TU / N73 M6 10 Nm

jacket), to engine block
6AZ Lower timing case cover to N62TU M8 20 Nm

crankcase
7AZ Upper timing case to cylinder N62TU M6 10 Nm

head
8AZ End cover, rear, to crankcase N62TU M6 10 Nm

Testing equipment
Connecting hose
Ã˜ = 8 x 13 mm, length = 70 mm
Sealing compound

Cartridge
Brake cleaner2.0 500 ml, 83192365214

Spray can
20 , 83192365215
Canister
lubricating grease Longtime PD -1 400 g, 83192160340

Cartridge
Copper paste 100 g, 81229400794

Tube
Lubricating grease SYNTHESO GLEP 1 100 g, 83299407778

Tube
Engine oil
Technically suitable engine oils for BMW Group

engines
3.0 Technically appropriate engine oils for BMW Group engines
Engine oil
Technically suitable engine oils for BMW Group

engines
3.0 Specified engine oils for Toyota J29
Sealing compound
Sealant Drei Bond 1209 30 ml, 07 58 9 062 376

Tube
12 21 Preheating Relay
Tightening Torques
1AZ Battery positive lead (terminal M41 / M51 4 Nm
30) to glow plug relay
2AZ 80 A fuse on glow plug relay M41 / M51 2 Nm
3AZ Battery positive lead (terminal M47/M57 / M67 5 Nm

12 23 Glow elements
Tightening Torques
specifications
1AZ Glow element M21 25 Nm
2AZ Glow element 4" M21 / M41 / 20 Nm

M51
M47 / M47TU / 13 Nm
M57 / M57TU /
M67 / M67TU
3AZ Connection bolt M21 / M41 / 4 Nm
M51
12 21 Preheating Relay
Tightening Torques
1AZ Battery positive lead (terminal M41 / M51 4 Nm
2AZ 80 A fuse on glow plug relay M41 / M51 2 Nm
3AZ Battery positive lead (terminal M47/M57 / M67 5 Nm

12 31 Alternator with Drive and Mounting Parts
Tightening Torques
specifications
1AZ Wires to alternator
Terminal D+ M10 / M20 5 Nm
alle / others M6 7 Nm
Terminal B+ S38 / B38 8 Nm
alle / others M8 13 Nm
2AZ Pulley alle 45 Nm
3AZ Belt pulley (drive belt) Alternator with 80 Nm

cooling jacket
All others 70 Nm
N42, N46 75 Nm
Valeo
N42, N46 65 Nm
Bosch
4AZ Rear retaining bracket alle 3,5 Nm
5AZ Cheese head screw for line clip alle 3,5 Nm
6AZ Alternator to bearing support M40 / M42 / 43 Nm

M43 / M44
7AZ Generator an KGH N42, N46, N62 M8 21 Nm
8AZ Ina belt pulley (drive belt) with 80 Nm

freewheel installed on Bosch
and Valeo alternator.
9AZ Alternator and deflecting M54 M10 x 150 42 Nm

element to support
Alternator to component carrier M10 x 125 42 Nm
10AZ Alternator to holder M57 M10 38 Nm
11AZ Idler pulley to holder M57 M8 19 Nm

12 32 Governor
Tightening Torques
Type thread tightening specification Torque
1AZ Regulator switch All M4 2 Nm
All M5 4 Nm
12 41 Starter and Mounting Parts
Tightening Torques
specification
1AZ Starter motor mounting to All, except 45 Nm
transmission bell housing N51, N52,
N52K, N53,
N54
2AZ Support to starter All M5 5 Nm
3AZ Support to crankcase All 47 Nm
4AZ Electrical leads to starter

All M5 5 Nm
All M6 7 Nm
All M8 13 Nm
5AZ Bolt connection, pole tube All M6 6 Nm
6AZ Heat shield to starter motor M6 6 Nm

12 42 Wires to starter
Tightening Torques
1AZ Battery positive terminal in/on E32 / E34 / M8 20 Nm
distribution box E31 / E36 /
E46 / E87 /
E90 / E85 / E86
/ E81
E39 / M57 M8 11 Nm
E38 / M67 M8 11 Nm
E46 / M47TU M8 11 Nm
E60 / N62 M8 15 Nm
E65 / N62 / N73 M8 15 Nm
2AZ Wiring harness on distributor E36 / M41 M8 10 Nm
12 51 Engine wiring harness
Tightening Torques
specification
1AZ Wiring harness on electrical M51 / M41 M5 2.5 Nm
cutout device
2AZ Wiring harness on distributor E36 / M41 M8 10 Nm
3AZ Battery positive terminal to M57 M8 7 Nm

intake manifold
4AZ Battery positive terminal in M62 / S62 M8 10 Nm

engine compartment
M57 / M67 M8 10 Nm
M54 M8 21 Nm
5AZ Wiring harness to ground M67 M6 10 Nm
holder
M47TU M6 7 Nm
M47T2 M6 9 Nm
6AZ DDE wiring harness pick-off to M47TU / M6 9 Nm
battery positive terminal M57TU / M67 /
M47T2
7AZ Injector guide strip to cylinder M47TU / 3.5 Nm
head cover M57TU
12 61 Oil pressure switch, oil level sensor (N47, N47S M47T, M47T2, M57T, M57T2)
Tightening Torques
specifications
1AZ Oil pressure switch to oil filter N47 / N47S M12x1.5 28 Nm
2AZ Oil level sensor to oil sump N47 / N47S / M6 8 Nm

M47T / M47T2 /
M57T / M57T2
12 61 Oil pressure, oil temperature, oil level display
Tightening Torques
specification
1AZ Oil-pressure switch/oil- All M12x1.5 27 Nm
temperature switch
2AZ Level switch for engine oil N62 / N73 / Jointing torque 2Â Nm 8.5 Nm
M67TU
3AZ Oil pressure switch N46 M12 x 1.5 27 Nm
4AZ Level sensor to oil sump N46 M6 9 Nm

12 72 Senders for Control Unit
Tightening Torques
1AZ Lever to pedal value sender E32 / E34 / 9 Nm
E31 / E36
2AZ Pedal value sender to pedal E32 / E34 / E31 5 Nm
console
12 90 Control Unit Housing
Tightening Torques
1AZ Assembly of upper and lower E32 / E34 / E36 5 Nm
sections
2AZ Center section to body E32 / E34 3 Nm
3AZ Control unit holder in E box E36 5 Nm
4AZ Control unit box cover E38 / E39 / E52 4 Nm
E46 6 Nm
E53 / E36/7 / 3 Nm
E54
5AZ Electronics box to firewall E65 Plastic screw 6 Nm
13 32 Fuel Filter
Tightening Torques
1AZ Fuel line to filter housing and
injection pump
Coupling nut M21 / M51 / M14 x 1.5 14 Nm

M41
Adapter M21 / M51 / M12 x 1.5 9 Nm
M41
Hollow bolt M21 / M51 / M14 x 1.5 14 Nm
M41
2AZ Fuel filter to holder M51 / M41 M8 22 Nm
3AZ Air duct to fuel cooler M47 5.7 Nm
M57 2 Nm
4AZ Fuel filter cover M47 25 Nm
5AZ Fuel filter with holder to body N42 8.8 Nm

13 51 Injection Pump, Control Receptacle
Tightening Torques
1AZ Plug for high pressure section M21 / M51 / 25 Nm
of injection pump M41
2AZ Distributor injection pump to M21 / M51 / 25 Nm

holder M41
3AZ Electric shutoff to injection M21 / M51 / 20 Â± 5

pump M41 Nm
4AZ Electric cold start valve to M21 20 Nm

injection pump
5AZ Coupling bolt (OUT) to injection M21 / M51 / 25 Nm

pump (fuel return) M41
6AZ Pressure valve holder to M21 / M51 45 Nm

injection pump
7AZ Expansion element housing M21 18 Nm

(temperature dependent idling
speed boost) to injection pump
8AZ Distributor injection pump to M21 / M51 / 22 Nm

flange and console M41
9AZ Electr. line on fuel cutout device M51 / M41 2.5 Nm
10AZ Fuel feed line to injection M47 30 Nm

pump (VP44)
11AZ Fuel return line to injection M47 25 Nm

pump (VP44)
12AZ Plug for static basic M47 13 Nm

adjustment (injection pump
VP44)
13AZ Blocking screw for injection M47 31 Nm

pump shaft without spacer
plate (injection pump VP44)
14AZ Blocking screw for injection M47 13 Nm

pump shaft with spacer plate
(injection pump VP44)
15AZ Injection line (union nut) to M47 30 Nm

injection pump (VP44)
13 52 Injection Pump Drive
Tightening Torques
1AZ Chain sprocket to injection M21 47 Nm
pump
2AZ Toothed belt pulley to injection M51 / M41 50 Nm

pump
Chain wheel on injection pump M47 18 Nm

(VP44) with blocked injection pump
drive shaft
Jointing torque
Chain wheel on injection pump M47 110 Nm

(VP44) with unblocked injection
pump drive shaft, gripped via
crankshaft central bolt
Tightening Torque
Sprocket wheel to H.P. pump M47TU / M14 x 1.5 65 Nm

(Common Rail System) M47T2 / M57 /
M57TU / M67 /
M57T2
3AZ Chain tensioner M51 15 Nm
13 53 Fuel Injector Nozzles and Lines
Tightening Torques
specifications
1AZ Nozzle holder combination M21 / M51 80 Nm
(assembly)
2AZ Injection nozzle assembly in M21 40 Nm

cylinder head
M51 / M41 65 Nm
3AZ Fuel injection line (union nut) to M21 / M51 / 20 Nm
injection pump and nozzle M41
combination
4AZ Feed line to fuel injection pipe M43 / 20 Nm

M44/M43TU
5AZ Injector nozzles - M47 M6 10 Nm
Combination in
Cylinder head cover
Injector in cylinder head cover M47TU / M47T2 M6 Establish the screw

(Common Rail System) / M57 / M57TU / connections alternately.
M57T2
1. Jointing torque 1 Nm
2. Jointing torque 4 Nm
3. Final torque 9 Nm
M67 M8 30 Nm
6AZ Fuel injection line to injection M47 30 Nm
pump (VP44) colour: yellow
chromated
up to 10/2000
Fuel injection line to injection M47 20 Nm

pump (VP 44)
Colour: grey phosphate coating
from 10/2000
7AZ Fuel injection line to injector M47 30 Nm

nozzle
Colour: yellow chromated
up to 10/2000
Fuel injection line to injector nozzle 20 Nm

from 10/2000
8AZ Pressure lines M57 / M47TU

(Common Rail System)
Injector 30 Nm
up to 10/2000
Injector M57TU M12 x 1.5 23 Nm

from 9/2002
Injector 20 Nm
from 10/2000
Pressure accumulator, 35 Nm
fuel distributor or
High pressure pump
up to 10/2000
Pressure accumulator, 20 Nm
fuel distributor or
High pressure pump
Colour: grey phosphate coated
from 10/2000
Pressure accumulator, M57TU M14 x 1.5 23 Nm

fuel distributor or
High pressure pump
from 9/2002
8AZ Pressure lines M67 / M47T2 /

(Common Rail System) M57T2
Injector 23 Nm
Pressure accumulator, fuel 23 Nm

distributor or high pressure pump
9AZ Rail pressure sensor to M57 RDS2 38 Nm

pressure accumulator (Common
Rail System)
M57 RDS4 38 Nm
M47TU / M57TU 70 Nm
/ M47TU2 /
M57TU2
10AZ Pressure regulator to high M57 / M67 9 Nm
pressure pump (Common Rail
System)
11AZ Pressure control valve to fuel E38 / M67 5 Nm

distributor (Common Rail
System)
E65 / M67 80 Nm
12AZ Rail pressure sensor to fuel E38 / M67 / 38 Nm
distributor (Common Rail RDS2
System)
E38 / M67 / 38 Nm
RDS4
E65 / M67 70 Nm
13AZ Rail pressure control valve to M47TU / M57TU 80 Nm
pressure accumulator
(Common Rail System)
M47TU2 / 1) Tightening 60 Nm
M57TU2
2) Opening by 90 °
3) Final torque 85 Nm
14AZ Fuel return line to rail M47TU / M57TU Banjo bolt 25 Nm
15AZ Fuel line to fuel injection pipe M56 26 Nm
16AZ Injector to fuel injection pipe M56 26 Nm
17AZ Threaded support sleeve to M57 60 Nm

rail
13 62 Senders for Control Unit
Tightening Torques
specification
1AZ Temperature time switch M21 / M51 18 Nm
2AZ Temperature sensor, water M60/1 / M60/2 / 18 Nm

M21 / M51
all others 13 Nm
3AZ Temperature switch All 28 Nm
4AZ Temperature sensor, air All 13 Nm
5AZ Charge-air pressure sensor to M51 / M41 4 Nm

bracket
Charge-air pressure sensor to M47 5 Nm

intake manifold
6AZ Dual temperature sensor M41 / M43 / 13 Nm

M44 / S50 /
(4-pin plug connection) S52 / M52 /
M57 / M67 /
M62 / M73
7AZ Air-mass sensor on lower M51 3.5 Nm
section of intake filter housing
Air-mass flow sensor to cylinder M47 / M47TU / 4.5 Nm

head cover M57 / M57TU /
M57T2
8AZ Pulse generator, camshaft to M57 4.5 Nm
cylinder head cover
M47TU / 3.5 Nm
M57TU
M57T2 2.3 Nm
9AZ Intake neck on air-mass flow M47 9 Nm
sensor
16 11 Fuel Tank and Mounting Parts
Tightening Torques
1AZ Fuel tank to body (hexagon E46 / E83 M8 Replace self-locking nuts 19 Nm
nut)
E24 M8 45 Nm
E30 M8 25 Nm
Tension strap to body (hexagon E53 / E46 / M8 19 Nm
screw) E85 / E86 / E83
E24 M8 8 Nm
E38 / E65 / M8 20 Nm
E66 / E67
E60 / E61 / M8 19 Nm
E63 / E64
2AZ Connecting pipe to fuel tank E30 25 Nm
3AZ Heat shield to fuel tank E30 8.5 Nm
E24 1.0 Nm
E31 3 Nm
4AZ Drain plug to fuel tank E28 / E30 25 Nm
5AZ Trunk separating wall/retaining E52 M6 7,8 Nm

bracket to trunk floor
6AZ Wheel arch cover to body E52 M6 3 Nm

16 12 Fuel Delivery
Tightening Torques
1AZ Pump assembly to metal- E28 / E30 6,5 Nm
bonded mount
2AZ Holder to fuel pump or fuel E28 / E30 6,5 Nm

reservoir
3AZ Electric connections on fuel E28 / E30 2 Nm

pump
4AZ Electric connections on fuel E28 / E30 M4 1,2 Nm

pump
5AZ Electric connections on fuel E28 / E30 M5 1,6 Nm

pump
6AZ Plastic nut on cover for fuel E30 2 Nm

pipes
7AZ Hose clamps 10 - 16 mm dia. E28 / E30 2 Nm
E65 / E66 1,5 Nm

8AZ Hose clamps 18 mm dia. E28 / E30 3 Nm
E52 3 Nm
E83 4 Nm
11AZ Fuel filler pipe to body E46 / E65 / 4 Nm
E66 / E67 / E83
E60 / E61 / M6 9 Nm
E63 / E64
E85 / E86 M6 8.8 9 Nm
12AZ Feed line to fuel tank E46 / M56 M14 26±3 Nm
13AZ Vent line from carbon canister E46 / M56 M24 26±3 Nm
to fuel tank
14AZ Fuel tank vent line to fuel filler E46 / M56 M14 26±3 Nm
pipe / purge air line to carbon
canister
16AZ Grounding strap, fuel filler pipe E85 / E86 M6 8.8 9 Nm

to body
E83 8 Nm
16 13 Tank Ventilation
Tightening Torques
1AZ Fuel vapor venting tank to E24 3 Nm
body
E30 4,5 Nm
E39 4,0 Nm
E38 5,5 Nm
E53 3,5 Nm
E65 / E66 / E67 9,0 Nm
2AZ Carbon canister to body E85 / E86 M8 9 Nm
E46 / E60 / M6 9 Nm
E61 / E63 /
E64 / E83
3AZ DMTL to holder / carbon E83 / E85 / 2 Nm
canister E86 / E60 / E46
/ M56
4AZ Dust filter to holder / carbon E60 / E83 / E46 2 Nm
canister / M56
E85 / E86 2 Nm
16 14 Fuel pump
Tightening Torques
specifications
1AZ Fuel level sensor to intake unit E32 8 Nm
2AZ Lock ring for fuel tank (sensor

opening, fuel level sensor,
pump unit)
Plastic lock ring 26.5 mm high E34 / E31 40 Nm
Plastic lock ring 31.5 mm high (new) E36 / E34 / E31 First manually tighten 55 Nm
lock ring by two rotations
Locking ring (metal) E39 / E46 / 35 Nm
E52 / E53
E60 / E61 / 45 ± 5 Nm
E63 / E64 /
E65 / E66 / E67
E85 / E86, 50 ± 10
Nm
E83 55±5 Nm
3AZ In-tank pump with fuel level E38 M6 Tighten nuts crosswise 6,5 Nm
sensor on tank
4AZ El. fuel pump control unit to E60 / E61 / M6 8 Nm

body / holder E63 / E64 /
E85 / E86
Front charge-air duct to fan cowl
5Nm
17 11 Radiator and Mounting Parts
Tightening Torques
specification
1AZ Radiator to body
self-tapping screw All B6.3 9 Nm
All M6 10 Nm
2AZ Drain plug to radiator All 2.5 Nm
3AZ Temperature switch to radiator All 15 Nm

(91 °C / 99 °C) max.
4AZ Expansion tank to body All 9 Nm
M57TU / E65 4 Nm
5AZ Radiator on module carrier E46 4 + 1 Nm
6AZ Retaining plate, expansion E46 4 + 1 Nm

tank, to radiator
7AZ Fan cowl on radiator E46 4 + 1 Nm
8AZ Plug in radiator (temperature E36/7 / M54 M14 x 1.5 15 Nm

switch omitted)
9AZ Mounting plate to radiator M57TU / E65 4.5 Nm
10AZ Radiator bracket All 2.5 Nm

17 40 Additional Fan (electric)
Tightening Torques
1AZ Electric auxiliary fan on fan cowl E46 6 Nm
2AZ Electronics for auxiliary fan on E46 6 Nm

fan cowl
17 22 Oil Cooler Pipes
Tightening Torques
1AZ Pipes to engine oil cooler All 25 Nm
2AZ Pipes to oil filter head E36 / M3 25 Nm
3AZ Holder on oil cooler pipes All 6 Nm
4AZ Bracket for oil cooler line to E36 / M3 M6 10 Nm

alternator
5AZ Oil cooling lines to oil filter unit E36 / E46 / E46 M8 20 Nm
carrier / S54
17 40 Additional Fan (electric)
Tightening Torques
1AZ Electric auxiliary fan on fan cowl E46 6 Nm
2AZ Electronics for auxiliary fan on E46 6 Nm

fan cowl
BMW antifreeze and corrosion inhibitor G30-91 1500 ml, 83192211662

DEU Can
60 l, 83192304076
Barrel
BMW antifreeze and corrosion inhibitor G30-91 1500 ml, 83512355294

Worldwide (except DEU, JPN, CHN, FIN, NOR, Can
SWE, DNK, FRO, AUS)
BMW antifreeze and corrosion inhibitor G30-91 60 l, 83512355295

Worldwide (except DEU) Barrel
BMW antifreeze and corrosion inhibitorG48 1500 ml, 83192211191

DEU Can
60 l, 83192304068
Barrel
205 l, 83192304069
Barrel
BMW antifreeze and corrosion inhibitor (i01) 1 l, 83512355296

Worldwide Can

Worldwide (except DEU, JPN, CHN, FIN, NOR, Can
SWE, DNK, FRO, AUS)
60 l, 83512355291
Barrel
205 l, 83512355293
Barrel

FIN, NOR, SWE, DNK, FRO Can

JPN Can

OFF Can

CHN Can
BMW antifreeze and corrosion inhibitor HT-12 5, 83192466484

Worldwide Canister
Technically suitable antifreeze and corrosion

inhibitor
Main group 17
18 00 Exhaust Assembly
Tightening Torques
specification
1AZ Primary catalytic converter to M57 / M57TU M10 42 Nm
turbocharger/or jacket pipe to
catalytic converter
M67 15 Nm
M30 / M70 Tighten down 10 Nm
compression spring with
nut uniformly to full
extent, then slacken by
1.5 turns
M51 Preload compression
springs with nut to 27±
1 mm
S50 M10 30 Nm
S54 / ECE M10 27 Nm
S54 / US M10 24 Nm
2AZ Exhaust pipe to flow section E23 25 Nm
3AZ Clamp for final muffler All M8 15 Nm
4AZ Catalytic converter on silencer E36 / M42 / Version with

M43 / M44 compression spring:
Evenly preload
compression springs
with nuts to 30 mm
5AZ Connection of positive and M73 5 Nm
negative leads to E catalytic
converter
6AZ Rear muffler to intermediate E53 M8 30 Nm

muffler
7AZ Vacuum tank to retaining plate E46 / M54 M8 10 Nm
8AZ Exhaust system to exhaust M40 / M42 / M10 45 Nm

manifold M43 / M44
9AZ Primary cat. to exhaust system M57TU / E65 55 Nm

18 00 Exhaust system, complete
Tightening Torques
specification
1AZ Primary catalytic converter to M47TU M8x40 clamp 15 Nm
exhaust turbocharger
2AZ Primary catalytic converter to M47TU M8 nut 21 Nm

support
3AZ Primary catalytic converter to M47TU Clamp 55 Nm

exhaust system
Diesel particulate filter cleaner 500 ml 83192211602
Starter kit for diesel particulate filter cleaner 500 ml 83192211603

21 11 Bell housing
Tightening Torques
1AZ Clutch housing to crankcase E36 / E38 / M8 28 Nm
E39 / E46 /
E52 / E53 /
E60 / E61 /
E63 / E64 /
E83 / E85 /
E87 / E90 / E91
E36 / E38 / M10 56 Nm
E39 / E46 /
E52 / E53 /
E60 / E61 /
E63 / E64 /
E83 / E85 /
E87 / E90 / E91
E36 / E38 / M12 98 Nm
E39 / E46 /
E52 / E53 /
E60 / E61 /
E63 / E64 /
E83 / E85 /
E87 / E90 / E91
21 21 Clutch Disc and Drive Plate
Tightening Torques
Type Thread Work instruction Torque
1AZ Clutch to flywheel E36 / E38 / M8 8.8 Replace screws 25 Nm
E39 / E46 /
E52 / E53 /
E60 / E61 /
E63 / E64 /
E83 / E85 /
E86 / E87 /
E90 / E91
E36 / E38 / M8 10.9 Replace screws 34 Nm
E39 / E46 /
E52 / E53 /
E60 / E61 /
E63 / E64 /
E83 / E85 /
E86 / E87 /
E90 / E91
Clutch to flywheel Replace ZNS bolts.
Jointing torque and
With angle of rotation must be
ZNS screws observed without fail.
S85 / S65 Jointing torque 15 Nm

N52 / N53 / M8 10.9 Jointing torque 15 Nm
N52K / M47T2 /
N45T / N54 /
N54T / N46T /
N43 / N45K /
N47 / M57T2 /
N47S / N62TU /
N55 / N57 / N20
Angle of rotation 90°±5°
Clutch to flywheel
M8 8.8 Tightening torque 25Nm

Renew screws.
M8 10.9 Tightening torque 34Nm

Renew screws.
M8 10.9 ZNS screw Jointing torque 15Nm

Renew screws.
Angle of rotation 90Â°
21 52 Clutch operation (hydraulic)
Tightening Torques
specification
1AZ Hydraulic line to clutch slave E36 / E38 / 14.5 Nm
cylinder or throttle. E39 / E52 /
E53 / E60 /
E61 / E63 /
E64 / E83 /
E85 / E86 /
E81 / E87 /
E90 / E91 / E92
E46 20 + 5 Nm
2AZ Clutch master cylinder to E36 / E38 / 22 Nm
bearing support E39 / E46 /
E52 / E53 /
E60 / E61 /
E63 / E64 /
E85 / E84 /
E86 / E87 /
E89 / E90 /
E91 / E92 / E93
E83 8 Nm
3AZ Fitting screw, clutch master E36 / E38 / 22 Nm
cylinder E39 / E46 /
E52 / E53 /
E60 / E61 /
E63 / E64 /
E83 / E85 /
E86 / E87 /
E90 / E91 /
E92 / E93
4AZ Clutch master cylinder to pedal E36 / E38 / 9 Nm
assembly E39 / E46 /
E52 / E53 /
E60 / E61 /
E63 / E64 /
E81 / E82 /
E83 / E84 /
E85 / E86 /
E87 / E88 /
E89 / E90 /
E91 / E92 / E93
5AZ Clutch slave cylinder to clutch E36 / E38 / 22 Nm
housing/transmission case E39 / E46 /
E52 / E53 /
E60 / E61 /
E63 / E64 /
E81 / E82 /
E83 / E84 /
E85 / E86 /
E87 / E88 /
E89 / E90 /
E91 / E92 / E93
E60 / E63 7-speed 25 Nm
SMG
6AZ Pressure accumulator to E36 / M3 35 Nm
hydraulic unit
7AZ Coupling bolts for hydraulic E46 / M3 14 Nm

pipes
8AZ Pressure accumulator for E46 / M3 40 Nm

hydraulic unit
9AZ Clutch position sensor to clutch E46 / E60 / 6-speed 2.5 Nm
slave cylinder E61 / E63 / SMG
E64 / E85
E60 / E61 / E63 7-speed 3.5 Nm
SMG
10AZ Banjo bolt, pipe, actuator/pump E60 / E61 / E63 7-speed 18 Nm
block SMG
11AZ Filler plug, expansion tank, E60 / E61 / E63 7-speed 2.1 Nm
pump block SMG
12AZ Throttle valve to clutch slave E60, E61 17 Nm

cylinder
Clutch slave cylinder to clutch housing/transmission housing
Renew screws. 22Nm

22 32 Transmission mounting
Tightening Torques
specifications
1AZ Bolt to transmission cross E60 / E65 / 30 Nm
member E66 / E67
2AZ Transmission bearing support to E60 / E61 / M10x35 ASA screw Isa flat-head 38 Nm
transmission E63 / E64 / screw
E65 / E66 /
E67 / E81 /
E82 / E84 /
E85 / E86 /
E87 / E88 /
E89 / E90 /
E91 / E92 /
E93
M10x32.5 48 Nm
3AZ Transmission mount to E60 / E61 / M8 19 Nm
transmission/transmission cross E63 / E64 /
member E67 / E81 /
E82 / E84 /
E85 / E86 /
E87 / E88 /
E89 / E90 /
E91 / E92 /
E93
4AZ Transmission cross member to E85 / E86 / M8 21 Nm
body E46 / E83
E60 / E61 / 19 Nm
E63 / E64 /
E67 / E81 /
E82 / E84 /
E87 / E88 /
E89 / E90 /
E91 / E92 /
E93
E53 M10 41 Nm
E70 / E71 / M10 38 Nm
E72
rubber mounts E83
E70 / E71 / M12 68 Nm

E72 / E84
6AZ Vibration absorber to E60 / E61 M10 38 Nm
transmission cross member
Tightening Torques
specifications
1AZ Bolt to transmission cross E60 / E65 / 30 Nm
member E66 / E67
2AZ Transmission bearing support to E60 / E61 / M10x35 ASA screw Isa flat-head 38 Nm
transmission E63 / E64 / screw
E65 / E66 /
E67 / E81 /
E82 / E84 /
E85 / E86 /
E87 / E88 /
E89 / E90 /
E91 / E92 /
E93
M10x32.5 48 Nm
3AZ Transmission mount to E60 / E61 / M8 19 Nm
transmission/transmission cross E63 / E64 /
member E67 / E81 /
E82 / E84 /
E85 / E86 /
E87 / E88 /
E89 / E90 /
E91 / E92 /
E93
body E46 / E83
E60 / E61 / 19 Nm
E63 / E64 /
E67 / E81 /
E82 / E84 /
E87 / E88 /
E89 / E90 /
E91 / E92 /
E93
E53 M10 41 Nm
E70 / E71 / M10 38 Nm
E72
rubber mounts E83
E70 / E71 / M12 68 Nm

E72 / E84
6AZ Vibration absorber to E60 / E61 M10 38 Nm
transmission cross member
Transmission cross member to body
M8 19Nm
Transmission mount to transmission/transmission cross member
M8 19Nm
23 00 Transmission in general
Tightening Torques
specifications
1AZ Transmission to engine
Transmission designations, see
23...
Hex screws B/C /D/E/F/ M6 8 Nm

G / H / I / 7‐
speed SMG
B/C /D/E/F/ M8 25 Nm
G / H / I / 7‐
speed SMG
B/C /D/E/F/ M10 49 Nm
G / H / I / 7‐
speed SMG
B/C /D/E/F/ M12 74 Nm
G / H / I / 7‐
speed SMG
Torx bolt B/C /D/E/F/ M6 9 Nm
G / H / I / 7‐
speed SMG
B/C /D/E/F/ M8 19 Nm
7‐speed SMG
B/C /D/E/H/ M10 43 Nm
I / 7‐speed
SMG
G-transmission M10 38 Nm
7‐speed SMG M10x55 8.8 43 Nm
7‐speed SMG M10x42 8.8 42 Nm
Steel screws with Torx head I/G/H/K M8 19 Nm
transmission
Steel screws with Torx head I/G/H/K M12 66 Nm
transmission
2Az Transmission to engine I / G / H- Replace screws Jointing
transmission torque and angle of
N52/N52K/N53/N54/N55 rotation must be
Aluminium screws/bolts are not observed without fail
magnetic.
I / G / H- M10x30 Jointing torque 20 Nm

transmission
Angle of rotation 90‐-110°
I / G / H- M10x85 Jointing torque 20 Nm
transmission
Angle of rotation 180‐-200°
I/G/H/K M12 Jointing torque 25 Nm
transmission
+20°
3AZ Cover plate, transmission I / H‐ M6 8 Nm
transmission
Tightening Torques
Transmission designation Type Thread Tightening Torque
specifications
2AZ Gearbox to clutch housing B/C /D/E/F/ M12 76 Nm
G / H / I / 7‐
speed SMG
3AZ Reinforcement shell to B/C /D/E/F/ M8 23 Nm
transmission G / H / I / 7‐
speed SMG
4AZ Oil drain plug / oil filler plug B/C 50 Nm
transmission
D / E- 52 Nm
transmission
G / H- M18x1.5 35 Nm
transmission hexagon
socket
H / I- M12x1.5 25 Nm
transmission
C / I- M18X1.5 Steel screw without 45 Nm
transmission gasket
7‐speed SMG 40 Nm
5AZ Transmission extension G / H- M10 46 Nm
transmission
Clutch slave cylinder to transmission
22Nm
Holder for underbody panelling

3Nm
Oil drain plug/oil filler plug (GS6-17DG)
M12x1.5 Tightening torque 25Nm
M18x1.5 steel screw without seal Tightening torque 45Nm
Oil drain plug/oil filler plug (GS6-37DG)
M12x1.5 Tightening torque 25Nm
M18x1.5 hexagon socket Tightening torque 35Nm
Transmission to engine
M8 19Nm
M12 66Nm
23 11 Case and Cover
Tightening Torques
specification
6AZ Reverse gear shaft to case B/C /D/E/F/ M8 25 Nm
G / H / I / 7-
speed SMG
S5D 310Z / S5D M8 20 Nm
320Z
B/C /D/E/F/ M10 45 Nm
G / H / I / 7-
speed SMG
7AZ Support for reverse gear shaft B / C- M8 25 Nm
transmission
8AZ Bearing holder to rear housing B / C- M6 10 Nm
section transmission
9AZ Retaining tabs for sealing cap C-transmission M6 10 Nm
10AZ Bearing on countershaft B-transmission M10 90 Nm
C-transmission M10 30 Nm
C-transmission M10 60 Nm
23 11 Case and Cover
Tightening Torques
specification
11AZ Screw plug to rear housing B/C /D/E/F/ M20 60 Nm
section G / H / I / 7-
speed SMG
B-transmission M16 40 Nm
B / C- M22 60 Nm
transmission
12AZ Sealing caps to rear housing B / C- M6 10 Nm
13AZ Reversing bolt to reversing ZFS-5-16 / C- 43 Nm

lever transmission
14AZ Clamping claw to rear housing ZFS-5-16 / C- 33 Nm

15AZ Screws on detent plate ZFS-5-16 / C- 9 Nm

transmission
23 11 Housing with lid
Tightening Torques
Transmission designation Type Thread Tightening Torque
specifications
1AZ Transmission housing, rear B/C /D/E/F/ 22 Nm
section/front section G / H / I / 7‐
speed SMG
2AZ Cover with guide B / C / D / E / F / M8 x 22 18 Nm
tube/transmission case G / H / I / C / 7‐
speed SMG
B / C / D / E / F / M8 x 30 25 Nm
G / H / I / C / 7‐
speed SMG
B / C / D / E / F / M6 10 Nm
G / H / I / C / 7‐
speed SMG
3AZ Bearing cap/sealing flange B/C /D/E/F/ 10,5 Nm
G / H / I / 7‐
speed SMG
4AZ Reverse gear wheel axle to B/C /D/E/F/ 49 Nm
intermediate housing G / H / I / 7‐
speed SMG
5AZ Retaining plate for reverse gear B / C / D / E / F / 25 Nm
wheel axle to intermediate G / H / I / 7‐
case speed SMG
6AZ Transmission closing plate B / C / D / E / F / M6 8 Nm

G / H / I / 7‐
speed SMG
7AZ Transmission oil strainer in G-transmission M18 25 Nm
transmission
23 11 Housing with lid
Tightening Torques
specifications
16AZ Retaining plate to 265 / Sport M6 9 Nm
intermediate housing
17AZ Retaining plates of bearings S5DÂ 310Z / M6 10 Nm

on housing S5D 320Z / S5D
200G / S5D
250G
18AZ Retaining plate to housing S5D 320Z SMG M6 5,5 Nm
23 21 Transmission shafts
Tightening Torques
specifications
1AZ Output flange S5D 200G / S5D Collar nut installed with
250G / S5D260Z / screw locking
S5DÂ 310Z / S6S
420G
Pretension 190 Nm
Release
Tighten down 120 Nm
S5D 280Z / S5D Collar nut installed with
320Z screw locking
Pretension 170 Nm
Release
Tighten down 130 Nm
S5D 390Z Collar nut installed with
screw locking
Pretension 200 Nm
Release
Tighten down 145 Nm
GS6-17BG / GS6- Collar nut installed with
37BZ screw locking
Pretension 170 Nm
Release
Tighten down 120 Nm
GS6-45BZ Collar nut installed with
screw locking
Pretension 200 Nm
Release
Tighten down 150 Nm
GS6-53DZ/BZ Collar nut installed with
screw locking
Pretension 200 Nm
Release
Tighten down 140 Nm
GS7S47BG Collar nut installed with 200 Nm
screw locking
2AZ Gear to countershaft 265 / Sport M10 60 Nm
3AZ Adapter shaft to the output GS6X45BZ 68 Nm

23 31 Interior Shift Components
Tightening Torques
specification
1AZ Shift arms to transmission case S5D 310Z 45 Nm
2AZ Sealing cap for locking sleeves S6S 420G M6 10 Nm

of gearshift rods
3AZ Retaining screw, shift actuator / S5D 320Z / M6 10 Nm

selector shaft S6S37BZ /
S6S53BZ SMG
23 41 External Gearshift Components
Tightening Torques
specifications
1AZ Servomotor / actuator to S6S 420G / M6 10 Nm
transmission housing GS6S37BZ /
GS7S47BG /
Insert screws with screw GS6S53BZ
locking adhesive SMG
transmission
2AZ Switch for gear recognition to S6S 420G SMG M5 6 Nm
servomotor transmission
3AZ Hydraulic lines to servomotor S6S 420G SMG M12x1 17 Nm

transmission
4AZ Actuator to transmission S6S 420G SMG M8 25 Nm
housing transmission
5AZ Reversing light switch B / C / D / E / F / M12 16 Nm

G / H / I / J / K-
gearbox
6AZ Pressure accumulator to valve GS5S31BZ / 30 Nm
block GS6S53BZ /
GS6S37BZ
SMG Gearbox
7AZ Protective plate GS5S31BZ / M6 10 Nm
GS6S53BZ /
Expansion tank GS6S37BZ
Shift actuator SMG Gearbox
Hydraulic pump
Valve block to transmission
housing
Ground strap to transmission
housing
8AZ Protective plate / valve block GS5S31BZ / M8 20 Nm

to transmission housing / GS6S53BZ /
GS6S37BZ
SMG Gearbox
9AZ Valves to valve block GS5S31BZ / M4 3.5 Nm
GS6S53BZ /
GS6S37BZ
SMG Gearbox
10AZ Pressure sensor to valve GS5S31BZ / 15 Nm
block GS6S53BZ /
GS6S37BZ
SMG Gearbox
11AZ Shift/selector sensor to GS5S31BZ / M4 2.8 Nm
transmission housing GS6S53BZ /
GS6S37BZ
SMG Gearbox
12AZ Retaining screw for hydraulic GS5S31BZ / 18 Nm
line GS6S53BZ /
GS6S37BZ
SMG Gearbox
13AZ Banjo bolt for hydraulic line GS5S31BZ 16 Nm
SMG Gearbox
14AZ Heat shield to expansion GS6S37BZ 6 Nm
tank/ pump bracket SMG Gearbox
15AZ Clutch speed sensor GS6S53BZ / 35 Nm

GS6S37BZ
SMG Gearbox
16AZ Transmission oil cooler to E60 / E63 / E64 / M6x35 10 Nm
transmission E61 /
GS7S47BG
SMG
transmission
17AZ Transmission oil strainer in E60 / E63 / E64 / M18 25 Nm
transmission oil cooler E61 /
GS7S47BG
SMG
transmission /
G-transmission
18AZ Banjo bolt to transmission oil E60 / E63 / E64 / M16x1.5 40 Nm
cooler E61 /
GS7S47BG
SMG
transmission
19AZ Union nut to screwed socket E60 / E63 / E64 / 40 Nm
E61 /
GS7S47BG
SMG
transmission
20AZ Oil cooler connection to E60 / E63 / E64 / 40 Nm
transmission oil cooler E61 /
GS7S47BG
SMG
transmission
21AZ Oil pump to transmission oil E60 / E63 / E64 / M6x20 10 Nm
cooler E61 /
GS7S47BG
SMG
transmission
22AZ Speed sensor to E60 / E63 / E64 / M6X16 10 Nm
transmission E61 /
GS7S47BG
SMG
transmission
23AZ Temperature and pressure E60 / E63 / E64 / 15 Nm
sensor to hydraulic unit E61 /
GS7S47BG
SMG
transmission
24AZ Clamp, pressure accumulator E60 / E63 / E64 / 22 Nm
to transmission E61 /
GS7S47BG
SMG
transmission
25AZ Pressure accumulator to E60 / E63 / E64 / 29 Nm
pump block E61 /
GS7S47BG
SMG
transmission
26AZ Pump block to transmission E60 / E63 / E64 / 22 Nm
E61 /
GS7S47BG
SMG
transmission
27AZ Banjo bolts, pressure lines E60 / E63 / E64 / 25 Nm
clutch actuator E61 /
GS7S47BG
and pump block SMG
transmission
28AZ Screws, actuator block E60 / E63 / E64 / 22 Nm
E61 /
GS7S47BG
SMG
transmission
29AZ Union nut, hydraulic line, E60 / E63 / E64 / 11 Nm
actuator block E61 /
GS7S47BG
SMG
transmission
30AZ Pump to electric motor E60 / E63 / E64 / 5 Nm

E61 /
GS7S47BG
SMG
transmission
31AZ Electric motor to pump block E60 / E63 / E64 / 5 Nm
E61 /
GS7S47BG
SMG
transmission
32AZ Screw plug to pump block E60 / E61 / E63 / 24 Nm
E64 /
GS7S47BG
SMG
transmission
33AZ Switch valve to actuator rack E60 / E61 / E63 / 2.9 Nm
E64 /
Clutch valve to pump rack GS7S47BG
SMG
transmission
Tightening Torques
specifications
1AZ Transmission mount (rubber B/C /D/E/F M10 42 Nm
mount) to cross member / G / H / I / 7‐
speed SMG
B/C /D/E/F M12 73 Nm
/ G / H / I / 7‐
speed SMG
2AZ Transmission cross member to B/C /D/E/F M10 42 Nm
body / G / H / I / 7‐
speed SMG
B/C /D/E/F M8 19 Nm
/ G / H / I / 7‐
speed SMG
B/C /D/E/F M8 Only E83,E85,E86,E46 21 Nm
/ G / H / I / 7‐
speed SMG
3AZ Bearing support to transmission B/C /D/E/F M8 19 Nm
/ G / H / I / 7‐
speed SMG
4AZ Transmission mounting bracket B/C /D/E/F M10 ASA 38 Nm
to transmission / G / H / I / 7‐ screw
speed SMG
B/C /D/E/F M10 ISA flat 48 Nm
/ G / H / I / 7‐ head
speed SMG
5AZ Transmission mount to B/C /D/E/F M8 19 Nm
transmission support / G / H / I / 7‐
bracket/transmission cross- speed SMG
member
Brake fluid and hydraulic fluid
Hydraulic fluid CHF 11 S 1 l, 83290429576

Can
Transmission oil
Manual gearbox oil MTF LT-5 1 l, 83222156969

Can
20 l, 83222167666
Barrel
Transmission oil
Manual gearbox oil MTF 3 1 l, 83222455210

Bottle
Transmission oil

* TU = Trade Unit. TU numbers cannot be ordered! Can
For invoicing purposes only.
5 l, 83220309031
Can
1000 ml, 83220396705
TU*
Transmission oil

5 l, 83227533818
Can
1000 ml, 83220396706
TU*
Transmission oil

5 l, 83220421925
Can
1000 ml, 83220430275
TU*
Transmission oil

20 l, 83220403247
Barrel
1000 ml, 83220403673
TU*
Transmission oil

1000 ml, 81229401225
TU*
Transmission oil
Technically suitable manual gearbox oil

Main group 23
Tightening Torques
specifications
1AZ Transmission to engine
Hex screws A4S 200R / M8 24 Nm

A4S 270R /
A4S 310R /
A5S 300J /
A5S 310Z /
A5S 325Z /
A5S 440Z /
A5S 560Z /
A5S 360R/A5S
390R /
GA6HP19Z /
GA6HP26Z /
GA6HP32Z
A4S 270R /
A4S 310R /
A5S 300J /
A5S 310Z /
A5S 325Z /
A5S 440Z /
A5S 560Z /
A5S 360R/A5S
390R /
GA6HP19Z /
GA6HP26Z /
GA6HP32Z
A4S 270R /
A4S 310R /
A5S 300J /
A5S 310Z /
A5S 325Z /
A5S 440Z /
A5S 560Z /
A5S 360R/A5S
390R /
GA6HP19Z /
GA6HP26Z /
GA6HP32Z
Torx bolts A4S 200R / M8 21 Nm
A4S 270R /
A4S 310R /
A5S 300J /
A5S 310Z /
A5S 325Z /
A5S 440Z /
A5S 560Z /
A5S 360R/A5S
390R
A4S 270R /
A4S 310R /
A5S 300J /
A5S 310Z /
A5S 325Z /
A5S 440Z /
A5S 560Z /
A5S 360R/A5S
390R
A4S 270R /
A4S 310R /
A5S 300J /
A5S 310Z /
A5S 325Z /
A5S 440Z /
A5S 560Z /
A5S 360R/A5S
390R
Torx bolts GA6HP19Z / M6 9 Nm

GA6HP26Z
Torx bolts GA6HP26Z M10 38 Nm
Steel Torx screws GA6HP19Z / M8 19 Nm

GA6L26Z /
GA6L45R
Steel Torx screws GA6HP19Z / M12 66 Nm
GA6HP26Z /
GA6L45R
2AZ Transmission to engine GA6HP19Z / Replace screws
N51/N52/N52K/N53/N54/N55 GA6HP26Z / Jointing torque and
Aluminium screws are not GA6L45R angle of rotation must
magnetic be observed without fail
GA6HP19Z / M10x30 Jointing torque 20 Nm

GA6L45R
Angle of rotation 90-110 °
GA6HP19Z M10x85 Jointing torque 20 Nm
Angle of rotation 180-200 °
GA6HP19Z / M12 Jointing torque 25 Nm
GA6L45R
3AZ Reinforcement shell to A4S 200R / M8 23 Nm
transmission/extension A4S 270R /
A4S 310R /
A5S 300J /
A5S 310Z /
A5S 325Z /
A5S 440Z /
A5S 560Z /
A5S 360R/A5S
390R /
GA6HP19Z /
GA6HP26Z /
GA6HP32Z
4AZ Cover plate for transmission GA6HP19Z / M6 9 Nm
GA6L45R
5AZ Heat shield, oil sump GA6L45R / M6 8 Nm
GA6HP19Z
6AZ Air duct plate GA6HP26Z M6 10 Nm
7AZ Line cover plate GA6HP26Z M6 10 Nm

Transmission to engine
Torx screwM6 9Nm
Torx screwM8 19Nm
Torx screwM12 66Nm

24 11 Transmission Case, Oil Sump
Tightening Torques
specification
8AZ Oil filler pipe 3HP-22 105 Nm
4HP-22 / 4HP- 98 Nm
24 / A5S 310Z
9AZ Plug A4S 200R / M18 43 Nm
A4S 270R /
A4S 310R /
A5S 300J / A5S
310Z / A5S
325Z / A5S
440Z / A5S
560Z / A5S
360R / A5S
390R /
GA6HP19Z /
GA6HP26Z /
GA6HP32Z
10AZ Oil duct screw plugs A5S 300J 8 Nm
A5S 310Z / 15 Nm
A5S 560Z
11AZ Damper cover on A5S 300J M6 10 Nm
transmission case
12AZ Radial shaft seal to converter A4S 270R / M4 3 Nm

housing A4S 310R /
A5S 360R /
A4S 360R
13AZ Intermediate plate on A4S 270R / 5/16 inch 25 Nm
intermediate housing A4S 310R
24 11 Transmission housing, transmission oil sump
Tightening Torques
specification
1AZ Transmission extension A4s 200R / A5S M8 25 Nm
300J / A5S
310Z / A5S
325Z / A5S
440Z / A5S
560Z / A5S
390R /
GA6HP19Z /
GA6HP26Z /
GA6HP32Z
A4S 270R / 5/16 inch 32 Nm
A4S 310R
A5S 360R / M8 22 Nm
A4S 360R
2AZ Guard A4s 200R / A5S M6 9 Nm
300J / A5S
310Z / A5S
325Z / A5S
440Z / A5S
560Z / A5S
390R /
GA6HP19Z /
GA6HP26Z /
GA6HP32Z
3AZ Converter housing A4s 200R / A5S M8 25 Nm
300J / A5S
310Z / A5S
325Z / A5S
440Z / A5S
560Z / A5S
390R /
GA6HP19Z /
GA6HP26Z /
GA6HP32Z
4HP-22 / 4HP- M10 46 Nm
24
A4S 270R / 1/2 inch 42 Nm
A4S 310R
4AZ Screw plug to intermediate A4s 200R / A5S M10 16 Nm
plate 300J / A5S
310Z / A5S
325Z / A5S
440Z / A5S
560Z / A5S
390R /
GA6HP19Z /
GA6HP26Z /
GA6HP32Z
4HP-22 / 4HP- M14 40 Nm
24
4HP-22 / 4HP- M20 50 Nm
24
A5S 440Z M12 23 Nm
24 11 Transmission housing, transmission oil sump
Tightening Torques
specification
5AZ Transmission oil sump 4HP-22 / 4HP- M6 6 Nm
24 / A5S 310Z /
A5S 325Z
A5S 560Z / M6 10 Nm
A5S 440Z
A4S 270R / M6 12 Nm
A4S 310R
A5S 360R / M6 10 Nm
A4S 360R
A5S 300J 9 Nm
GA6HP26Z / M6 10 Nm
GA6HP19Z /
GA6L45R /
GA6HP32Z
6AZ Oil drain plug A4S 200R / M10 16 Nm
A5S 310Z /
A5S 325Z 35 Nm
A5S 440Z M16x1.5 30 Nm
A5S 560Z 50 Nm
A5S 360R / M14 18 Nm
A5S 390R
A4S 270R / 25 Nm
A4S 310R
A5S 300J 35 Nm
GA6L45R M12x1.75 14 Nm
GA6HP19Z / M10x1 Metal oil sump 12 Nm
GA6HP26Z /
GA6HP32Z
GA6HP19Z / M16x1.5 Plastic oil sump 8 Nm
GA6HP26Z / M24x1
GA6HP32Z
7AZ Oil filler plug A5S 325Z 30 Nm
A5S 310Z / 100 Nm

A5S 560Z
A5S 440Z M18x1.5 35 Nm
A4S 270R / 33 Nm
A4S 310R
A5S 360R / M14 18 Nm
A4S 360R
A5S 300J 40 Nm
GA6HP26Z / M30x1.5 80 Nm
GA6HP32Z
GA6HP19Z / M18x1.5 35 Nm
GA6HP26Z /
GA6HP32Z
GA6L45R M18x1.5 19 Nm
Oil filler plug (GA6HP and GA8HP)
M18 Tightening torque 35Nm

The torque to be set deviates from the specified
tightening torque due to the special tool. The torque to Torque to be set Torque to be set=(35 Nm * L1) : L2
be set must be calculated depending on the used
torque.
24 13 Transmission Extension, Bearings, Sealing Ring
Tightening Torques
specifications
1AZ Slotted nut / output flange A5SÂ 310Z / 120 Nm
A5S 440Z / A5S
560Z / A5S
325Z
2AZ Double hexagon nut/output GA6HP26Z up to 09/02 80 Nm
flange without sealing ring in
output flange
GA6HP19Z / from 09/02 60 Nm
GA6HP26Z with sealing ring in output
flange
GA8HP45Z with sealing ring in output 60 Nm
flange
3AZ Output shaft nut to output GA6L45R Replace nut 55 Nm
flange from 01/11
Nut with screw locking in
thread
24 15 Electrical fittings
Tightening Torques
specification
1AZ Position switch on transmission A4S 200R / M6 10 Nm
A4S 270R /
A4S 310R /
A5S 300J / A5S
310Z / A5S
325Z / A5S
440Z / A5S
560Z / A5S
360R / A5S
390R /
GA6HP19Z /
GA6HP26Z /
GA6HP32Z
24 21 Input, Intermediate and Output Shafts
Tightening Torques
1AZ Flange nut, output flange A5S 300J 225 Nm
Flange nut, output flange without A5S 360R 30 Nm

spring washer
Flange nut, output flange, with A5S 360R / 60 Nm

spring washer A5S 390R /
A4S 200R
A4S 270R / 100 Nm
A4S 310R
24 22 Planetary gear drive
Tightening Torques
1AZ Brake coupling D/G on gear A5S 310Z / M10
box housing A5S 560Z
Insert all screws until

contact is made with
screw head in each case
center bolt 30 Nm
both outer screws 15 Nm
center bolt 63 Nm
24 23 Shift Clutches
Tightening Torques
1AZ Torx screws for F clutch on 4HP-22 / 4HP- M6 10 Nm
transmission case 24
/ A5SÂ 560Z M8 23 Nm
2AZ Brake band adjusting screw A 4 S 270 R / A 5/16" 5 Nm
4 S 310 R
3AZ Lock nut of brake band A 4 S 270 R / A 5/16" 21 Nm
adjusting screw 4 S 310 R
24 30 Hydraulic / electric control parts and controlling elements
Tightening Torques
specifications
1AZ Valve body to transmission 3HP-22 M6 11 Nm
4HP-22 / 4HP-24 M6 8 Nm
/ A5S 310Z /
A5S 440Z / A5S
300J / A5S
325Z /
GA6HP19Z /
GA6HP26Z /
GA6HP32Z
GA6HP19Z TU / M6 8 Nm
GA6HP26TU
A4S 270R / A4S 5/16 inch 20 Nm
310R
A5S 360R / M6 11 Nm
A4S 360R
A5S 560Z M6 x 12 6 Nm
A5S 560Z M6 x 55 8 Nm
GA6L45R M5 8 Nm
2AZ Valve housing to valve body A4S 200R / A4S M6 5 Nm
270R / A4S
310R / A5S
300J / A5S
310Z / A5S
310Z / A5S
440Z / A5S
560Z /
A5S 360R / A5S
390R /
GA6HP19Z /
GA6HP26Z /
GA6HP32Z
3AZ Intermediate plate on shift unit A4S 270R / A4S 13 Nm
310R
4AZ Input and output speed M6 12 Nm
sensors to mechatronics
24 31 Primary Pump
Tightening Torques
specification
1AZ Oil pump to case
A4S 270R / 5/16 inch
A4S 310R
1st pass 10 Nm
2nd pass 20 Nm
A5S 560Z M6 10 Nm
A5S 560Z M5 5 Nm
A5S 300J / A5S M6 11 Nm
440Z / A5S
310Z / A5S
325Z
GA6HP19Z / M6 10 Nm
GA6HP26Z
2AZ Oil strainer A5S 440Z / 5 Nm
A5S 560Z
A5S 310Z 6 Nm
A5S 325Z M6 6 Nm
A4S 270R / 5/16 inch 20 Nm
A4S 310R
A5S 300J 8 Nm
3AZ Oil pump body A4S 270R / 5/16 inch 20 Nm
A4S 310R
A5S 310Z / M6 10 Nm
A5S 560Z
GA6HP19Z / 10 Nm
GA6HP26Z
4AZ Oil cooler pipe adapter to A5S 300J / 28 Nm
transmission A4S 270R /
A4S 310R
Hollow bolt A5S 440Z M18x1.5 25 Nm
Cap screw A5S 440Z M18x1.5 20 Nm

24 32 Controller
Tightening Torques
specifications
1AZ Governor A4S 200R / A4S 270R / A4S 310R / A5S 300J / M8 16 Nm
flange to A5S 310Z / A5S 325Z / A5S 440Z / A5S 560Z /
transmission A5S 360R / A5S 390R / GA6HP19Z / GA6HP26Z /
GA6HP32Z
2AZ Threaded A4S 200R / A4S 270R / A4S 310R / A5S 300J / M6 3 Nm
bolt to A5S 310Z / A5S 325Z / A5S 440Z / A5S 560Z /
centrifugal A5S 360R / A5S 390R / GA6HP19Z / GA6HP26Z /
governor GA6HP32Z
3AZ Hexagon nut A4S 200R / A4S 270R / A4S 310R / A5S 300J / 10 Nm
to threaded A5S 310Z / A5S 325Z / A5S 440Z / A5S 560Z /
bolt A5S 360R / A5S 390R / GA6HP19Z / GA6HP26Z /
GA6HP32Z
4AZ Hexagon A4S 200R / A4S 270R / A4S 310R / A5S 300J / M6 11 Nm
screw to A5S 310Z / A5S 325Z / A5S 440Z / A5S 560Z /
centrifugal A5S 360R / A5S 390R / GA6HP19Z / GA6HP26Z /
governor GA6HP32Z
5AZ Governor 4HP-22H M6 11 Nm

housing to
hub
24 34 Shift travel valves, parking lock
Tightening Torques
specification
1AZ Pressure regulator to valve 4HP-22EH / M6 5 Nm
housing 4HP-24EH /
A5S 310Z
A4S 270R / 10 Nm
A4S 310R
2AZ Solenoid valve to valve 4HP-22EH / M6 5 Nm
housing 4HP-24EH /
A5S 310Z
A4S 270R / 10 Nm
A4S 310R
A5S 560Z 6 Nm
A5S 300J M5 3 Nm
A5S 300J M6 8 Nm
3AZ Guide Plate / Parking Lock A5S 310Z 10 Nm
Mechanism
A5S 325Z 10 Nm
A5S 560Z 23 Nm
A5S 360R / M6 21 Nm
A4S 360R
A5S 440Z M6 10 Nm
4AZ Pulse sender A5S 310Z / M5 5 Nm
A5S 440Z
A5S 560Z M5 6 Nm
M8 23 Nm
A5S 360R / M6 11 Nm
A4S 360R
A5S 300J M5 6 Nm
5AZ Cover for servo piston on shift A4S 270R / 5/16 inch 25 Nm
unit A4S 310R
6AZ Retaining plate for solenoid A5S 440Z M5 5 Nm

valves and pressure regulator
on shift unit
A5S 325Z 6 Nm
7AZ Retaining plate for solenoid GA6HP19Z / 5 Nm
valves and GA6HP26Z
EDS valves to hydraulic unit
8AZ Electronic module to GA6HP19Z / 8 Nm

GA6HP26Z
hydraulic unit
24 34 Shift Valves, Parking Lock
Tightening Torques
7AZ Pulse generator, output speed A5S 325Z 6 Nm
8AZ Pulse generator, turbine speed A5S 325Z 8 Nm
9AZ Plug A5S 325Z 20 Nm

24 35 Wire Harness, Shift Elements and Sensor
Tightening Torques
1AZ Transmission socket to case 4HP-22 EH / 4 M26 12 Nm
HP-24EH /
A5S 310Z
A4S 270R / M26 14 Nm
A4S 310R
24 40 Torque converter
Tightening Torques
specification
1AZ Torque converter to flywheel M8 26 Nm
A4S 270R / M10 8.8 45 Nm

A4S 310R /
A5S 310Z / A5S
300J / A5S
440Z / A5S
560Z / A5S
325Z / A4S
200R /
GA6HP26Z /
GA6HP19Z
A5S360/ 390R M10 45 Nm
A5S360/ 390R / M10 10.9 56 Nm
GA6HP19Z /
GA6HP26Z /
GA6HP32Z /
GA6L45R
Torque converter on the drive plate
M10 56Nm
Renew screws.
24 51 External shift linkage
Tightening Torques
specification
1AZ Selector lever on transmission A4S 200R / M8x1 10 Nm
A4S 270R /
A4S 310R /
A5S 310Z / A5S
325Z / A5S
440Z / A5S
560Z / A5S
360R / A5S
390R /
GA6HP19Z /
GA6HP26Z /
GA6 HP32Z /
GA6L45R
A5SÂ 300J M8 15 Nm
24 52 Interior Shift Elements
Tightening Torques
specification
1AZ Shift segment to shaft A4S 270R / 22 Nm
A4S 310R
A5S 300J M14x1.5 35 Nm
2AZ Detent spring on shift unit A4S 270R / 5/16" 25 Nm
A4S 310R
Tightening Torques
specification
1AZ Cross member to body E36 / E38 / 21 Nm
E39 / E46 /
E53 / E85 /
E86 / E83
E60 / E61 / M8 19 Nm
E63 / E64 /
E66 / E67 /
E68 / E65 /
E83 / E81 /
E87 / E93 /
E92 / E91 /
E90 / E88 /
E82 / E89 /
E84
2AZ Rubber mounts to cross E36 / E38 / 21 Nm
member or transmission E39 / E46 /
E53
E81 / E60 / 19 Nm
E61 / E63 /
E64 / E65 /
E66 / E87 /
E93 / E92 /
E91 / E90 /
E87 / E86 /
E85 / E68 /
E67 / E88 /
E82 / E89 /
E84
E83 73 Nm
3AZ Support tube to engine E36 42 Nm
subframe
4AZ Rubber mounts to carrier pipe E36 21 Nm
5AZ Carrier plate E36 21 Nm
6AZ Transmission support block to E60 / E61 / ASA screw 38 Nm

transmission E63 / E64 /
E87 / E85 /
E86 / E87 /
E90 / E91 /
E92 / E93 /
E81 / E82 /
E88 / E84
E60 / E61 / M10 M10 ISA pan-head screw 48 Nm
E63 / E64 /
E87 / E85 /
E86 / E87 /
E90 / E91 /
E92 / E93 /
E81 / E82 /
E88 / E84
7AZ Transmission mount to E60 / E61 / 19 Nm
transmission support E63 / E64 /
bracket/transmission cross- E87 / E90 /
member E91 / E92 /
E93 / E81 /
E82 / E88 /
E84
Transmission oil
Automatic transmission fluid ATF D II 1 l, 81229400272

Can
60 l, 81229400275
Barrel
Transmission oil
Automatic transmission fluid ATF D VI 1 l, 83222167718

Can
5 l, 83222167720
Barrel
Transmission oil
Automatic transmission fluid ATF 1 1 l, 83222305395

Can
5 l, 83222344588
Can
Transmission oil

Bottle
20 l, 83229407807
Barrel
Transmission oil

Bottle
20 l, 83220442817
Barrel
Transmission oil

Bottle
20 l, 83222355601
Barrel
Transmission oil
Automatic transmission fluid JWS 3309 1 l, 83227542290

Bottle
Transmission oil
Automatic transmission fluid ATF 3+ 1 l, 83222289720

Bottle
Transmission oil

* TU = Trade Unit. TU numbers cannot be ordered! Barrel
1000 ml, 83220406574
TU*
Transmission oil
Automatic transmission fluid ATF D III 1 l, 83229407858

1000 ml, 83229407860
TU*
Transmission oil

20 l, 83220142516
Barrel
1000 ml, 83220144137
TU*
25 11 Shift Console - Manual Transmission
Tightening Torques
specification
1AZ Front console to shift console E36 / E38 / 25 Nm
E39 / E46 /
E53 / E60 /
E61 / E63 /
E64 / E83 /
E85 / E86 /
E87 / E90 /
E91 / E92, with
sheet metal
console
2AZ Shift console to transmission E36 / E38 / 23 Nm
E39 / E46 /
E53 / E60 /
E61 / E63 /
E64 / E83 /
E85 / E86 /
E87 / E90 /
E91 / E92, with
sheet metal
console
3AZ Rear shift console to body E36 / E38 / 11 Nm
E39 / E46 /
E53 / E60 /
E61 / E63 /
E64 / E83 /
E85 / E86 /
E87 / E90 /
E91 / E92
4AZ Aluminium shift arm console to E30 / M3 21.5 Nm
transmission
5AZ Aluminium shift arm to console E30 / M3 11 Nm
6AZ Shift arm console to body E36 / E38 / 21 Nm

E39 / E46 /
E53 / E60 /
E61 / E63 /
E64 / E83 /
E85 / E86 /
E87 / E90 /
E91 / E92
E31 9 Nm
7AZ Adjustable shift rod (clamping E31 23 Nm
sleeve)
8AZ Support bearing to E53 21.5 Nm

transmission tunnel
10AZ Hose clamp, vibration damper E60 / E61 6 Nm

Wishbone to body
M6 10Nm
25 16 Gearshift bracket - Automatic Transmission
Tightening Torques
specifications
1AZ Bowden cable to gearshift E36 / E38 / 15 Nm
bracket/transmission E39 / E46 /
E53 / E60 /
E61 / E63 /
E64 / E65 /
E66 / E67 /
E68 / E83 /
E85 / E86 /
E87 / E90 /
E91 / E92 /
E81 / E82 / E88
2AZ Clamping screw on shift lever E36 / E38 / 10 Nm
E39 / E46 /
E53 / E60 /
E61 / E63 /
E64 / E65 /
E66 / E67 /
E68 / E83 /
E85 / E86 /
E87 / E90 /
E91 / E92 /
E93 / E81 /
E82 / E88 /
E89 / E84
3AZ Gearshift bracket to tunnel E36 / E38 / 7 Nm
E39 / E46 /
E53 / E60 /
E61 / E63 /
E64 / E65 /
E66 / E67 /
E68 / E83 /
E85 / E86 /
E87 / E90 /
E91 / E92 /
E93 / E81 /
E82 / E88 /
E89 / E84
4AZ Switch to gearshift bracket E36 / E38 / 4,5 Nm
E39 / E46 /
E53 / E60 /
E61 / E63 /
E64 / E65 /
E66 / E67 /
E68 / E83 /
E85 / E86 /
E87 / E90 /
E91 / E92
5AZ Interlock cable to gearshift E36 / E38 / 7 Nm
bracket E39 / E46 /
E53 / E60 /
E61 / E63 /
E64 / E65 /
E66 / E67 /
E68 / E83 /
E85 / E86
6AZ Cable retaining tab to E91 / E92 M8X18 19 Nm
transmission 4WD / E84
N55
7AZ Oval-head screw for emergency E60, E61 1,6 Nm
release device
8AZ Screw for adjusting cable on E60 / E61 / With ball head 13 Nm
E83 / E84 /
E87 / E88 /
E90 / E91 /
E92 / E93
9AZ Vulcanised support angle to E81 / E82 / M6 9 Nm
E90 / E91 /
E92 / E93 / E84
10AZ Nut, support angle E60 / E61 / M8 19 Nm
E81 / E82 /
E83 / E84 /
E87 / E88 /
E90 / E91 /
E92 / E93
Clamping bolt to lever
10Nm
26 11 Propeller Shaft. complete
Tightening Torques
specifications
1AZ Flexible disc to propeller shaft E36 / E38 / M10 8.8 48 Nm
and transmission output flange E39 / E46 /
E52 / E53 /
Steel propeller shaft E60 / E61 /
E63 / E64 /
E65 / E66 /
E83 / E85 /
E87 / E90 / E91
E36 / E38 / M10 10.9 64 Nm
E39 / E46 /
E52 / E53 /
E60 / E61 /
E63 / E64 /
E65 / E66 /
E83 / E85 /
E87 / E90 / E91
E31 / E38 / M14 140 Nm
E39 / E46
E32 / E34 / M12 8.8 81 Nm
E36 / E38 / E39
E60 / E61 / M12 8.8 90 Nm
E63 / E64
E32 / E34 / M12 10.9 100 Nm
E36 / E38 /
E39 / E46 /
E53 / E85
E60 / E61 / M12 10.9 Jointing torque 55 Nm
E63 / E64
E39 (M5) / E36 M12 10.9 115 Nm
(M3) / E46
(M3),
E65 M12 10.9 90 Nm
Flexible disc to transmission output E46 / E39 / E60 Screw with rolled-on
flange / OnlyM57 washer only
Flexible disc to transmission output E65 / E66 / All Screw with rolled-on
flange except N73, washer only
M67
E60 / E61 / M12 10.9 Double-stage flexible
E63 / E64 / disc
E65 / E66 / E67
Angle of rotation 90°
Flexible disc on propeller shaft E83 M12 10.9 Tighten via nut 100 Nm
Flexible disc to transmission output E83 M12 10.9 90 Nm

flange
Aluminium propeller shaft: Flexible E39 / E60 M12 10.9 100 Nm

disc to transmission output flange
Aluminium propeller shaft: Flexible E39 / E60 M12 10.9 90 Nm

disc on propeller shaft
E60 / E61 / M10 10.9 64 Nm
E63 / E64
E60 M12 8.8 90 Nm

E63 (N52) M12 110 Nm
Flexible disc to transmission output Replace bolts and nuts
flange Jointing torque and angle
of rotation must be
ZNS screws and nuts observed without fail
Shiny zinc coating
All versions
E60 / E61 / M10-10.9 Jointing torque 20 Nm

E63 / E64 /
E85 / E86 /
E87 / E90 /
E91 / E92 /
E93 / E81 /
E82 / E83 /
E84 / E88 / E89
E60 / E61 /
E63 / E64 /
E65 / E85 /
E86 / E87 /
E90 / E91 /
E92 / E93 /
E70 / E71 /
E72 / E81 /
E82 / E83 /
E84 / E88 / E89
E63 / E64 / E65
E83 M12- 10.9 Jointing torque 30 Nm
Screw with ribbed teeth +
double stage flexible disc
2AZ Coupling propeller shaft to E36 / E38 / M10 60 Nm
E52 / E53 /
E60 / E61 /
E63 / E64 /
E65 / E66 /
E83 / E85 /
E87 / E90 / E91
E32 / E31 M12 95 Nm
3AZ Clamping ring for slide after E36 / E38 / 10 Nm
installation in the car E39 / E46 /
E52 / E53 /
E60 / E61 /
E63 / E64 /
E65 / E66 /
E83 / E85 /
E87 / E90 / E91
E30 / All-wheel 22 Nm
drive vehicle
26 11 Propeller Shaft. complete
Tightening Torques
specifications
4AZ Propeller shaft to drive
flange (rear axle final drive)
Version, universal joint: E36 / E38 / E39 / E46 / M10 Only finned nuts to 64 Nm
E52 / E53 / E60 / E61 / higher tightening
Compression nut E63 / E64 / E65 / E66 / torque
E83 / E85
Version, universal joint: E36 / E38 / E39 / E46 / M10 85 Nm
E52 / E53 / E60 / E61 /
Torx bolt E63 / E64 / E65 / E66 /
E83 / E85
Version, constant-velocity joint: E46 (M3) / E38/ E39/ M10 70 Nm
E46 / E60 /
Torx bolt E83(M57TU)E63(N52)
Version, constant-velocity joint: E36 / E38 / E39 / E46 / M8 32 Nm

E52 / E53 / E60 / E61 /
Compression nut E63 / E64 / E65 / E66 /
E83 / E85
Compression nut E36 / E38 / E39 / E46 / M10 64 Nm
E52 / E53 / E60 / E61 /
E63 / E64 / E65 / E66 /
E83 / E85
Finned nut E36 / E38 / E39 / E46 / M8 43 Nm
E52 / E53 / E60 / E61 /
E63 / E64 / E65 / E66 /
E83 / E85
Finned nut E36 / E38 / E39 / E46 / M10 70 Nm
E52 / E53 / E60 / E61 /
E63 / E64 / E65 / E66 /
E83 / E85
ZNS screws and nuts, shiny Replace bolts and nuts
zinc coating Jointing torque and
angle of rotation must
All versions with universal or be observed without
constant-velocity joint fail
E83 / E85 / E86 / E87 / M10-10.9 Jointing torque 40 Nm
E90 / E91 / E92 / E93 / screw with
E81 / E82 / E84 / E88 ribbed teeth
E92 M3 / E82 M M10 screw Jointing torque 20 Nm
Coupé with ribbed
teeth
E46 / E60 / E61 / E63 / M10-10.9 Jointing torque 20 Nm
E64 / E65 / E66 / E83 /
E85 / E86 / E81 / E82 /
E87 / E90 / E91 / E92 /
E93 / E88 / E84
E90 / E91 / E92 / E93 / M12x55- Jointing torque 55 Nm
E81 / E87 / E82 / E83 / 10.9
E88 / E84
Screw with ribbed teeth E85 / M, E86 / M M10x46- Replace screws and 70 Nm
10.9 washers
5AZ Pivot fork piece to centre E36 / E38 / E39 / E46 / 97 Nm
propeller shaft bearing E52 / E53 / E60 / E61 /
journal with Loctite E63 / E64 / E65 / E66 /
E83 / E85 / E86 / E87 /
(Version without slide) E90 / E91 / E92
6AZ Centre mount to body E36 / E38 / E39 / E46 / 21 Nm

E52 / E53 / E60 / E61 /
E63 / E64 / E65 / E66 /
E70 / E71 / E72 / E81 /
E83 / E82 / E84 / E85 /
E86 / E87 / E88 / E89 /
E90 / E91 / E92 / E93
7AZ Flexible disc to front axle E53 M10-10.9 60 Nm
differential
8AZ Flexible disc on propeller E53 M10-10.9 64 Nm

shaft
9AZ Front propeller shaft to Replace bolts and nuts

transfer box/front Jointing torque and
differential angle of rotation must
ZNS screws and nuts, be observed without
shiny zinc coating fail
E60 / E61 / E90 / E91 / M8 Jointing torque 20 Nm

E92 / E84 / E70 / E71
E46 M10-10.9 Jointing torque 20 Nm
E53 / E70 / E71 / E72 M10-12.9 Jointing torque 10 Nm
E46 M10x1.5 Jointing torque 5 Nm
10.9
Universal joint E70 / E71 / E72 / E83 M10-10.9 Jointing torque 40 Nm
Centre mount to body
21Nm
Front flexible disc on the transmission

Renew screws and nuts. Tightening via screw.
Jointing torque 55Nm
Front flexible disc on the transmission

Different screws may be installed. Select the correct torque according to the screw connection. ZNS screw can be
recognized by the fact that they are coated with shiny zinc.
M10 8.8 48Nm
M10 10.9 64Nm
M12 10.9 90Nm
ZNS screw with nut M10 10.9 Jointing torque 20Nm

Renew screws and nuts.

Renew screws and nuts.
Propeller shaft (universal joint) to rear axle differential

Different screws may be installed. Select the correct torque according to the screw connection.
ZNS screw with nut M10 10.9 Ribbed serration Jointing torque 40Nm
Renew ZNS screw and nut.


Lubricating grease Optitemp HT 1 LF 50 g, 83230417754

Tube
Lubricating grease Olistamoly 2 LN 584 LO 100 g, 83 19 0 447 919

Tube
Transmission oil
Transfer box oil DTF 1 1 l, 83222409710

Bottle
Transmission oil
Hypoid Axle Oil G1 3x 500 ml, 83222295532

Bottle
Mounting grease GE 5 g, 83232357146

Tube
Transmission oil
Technically suitable transfer box and electrical

transmission oils
Main group 27
Solvent cleaner GE 300 ml, 83232357553

50 ml, 83232288661
TU*
Transmission oil
Double-clutch transmission oil DCTF-1+ 1 l, 83222446673

Bottle
Twin-clutch gearbox oil BMW DCTF-2 1, 83 22 2 433 157

Bottle
31 10 Front Axle Suspension
Tightening Torques
specification
1AZ Front axle carrier to engine E30, E31, E32, M10 8.8 Replace screws 42 Nm
carrier E34 (E30 AWD insert with
Loctite)
E30, E31, E32, M10 9.8 Replace screws 47 Nm
E34
E36 M12 12.9 Replace screws 105 Nm
E36, E46 M12 10.9 Replace screws 110 Nm
E38, E39 M12 8.8 Replace screws 77 Nm
E52 M12 Replace screws 75 Nm
front 10.9
middle 8.8
rear 8.8
E53, E60 / M12 10.9 Observe repair 100 Nm
Rear end, E61 instruction.
/ Rear end,
E63, E64, E65,
E66, E67, E85,
E86
E60 / Four M12 10.9 Observe repair
Wheel Drive, instruction.
E61 / Four Replace screws
Wheel Drive
Torque angle 90 °
2AZ Front end of front axle carrier to E34 / Four M10 8.8 47 Nm
body Wheel Drive
E83 M12 10.9 113 Nm

3AZ Front axle subframe rear / E34 / Four (collar 59 Nm
middle to body Wheel Drive screw)
E83 M10 10.9 50 Nm

E83 M12 10.9 100 Nm
4AZ Front axle carrier with E31 47 Nm
reinforcement to engine carrier
5AZ Cruciform reinforcement to door E31 42 Nm

sill
6AZ Reinforcement to bracket E31 42 Nm

Bracket to body
7AZ Reinforcement (sleeve) to E31 127 Nm

body
8AZ Front end reinforcement on E46 Replace screws;

front axle carrier/engine carrier first tighten down rear
screws
Torque angle 90+30 °
9AZ Reinforcement plate to front E53 Replace screws & nuts
axle support/engine carrier
Torque angle 90 °
E60 / Rear Replace screws & 56 Nm
end, E61 / insertion nuts
Rear end, E63,
E64, E65, E66,
E67
Torque angle 90 °
E60 / Four Replace screws
Wheel Drive,
E61 / Four
Wheel Drive
Torque angle 90 °
E83 M10 Replace screws 74 Nm
10AZ Adapter to body E46 / Four Replace screws 59 Nm
Wheel Drive
11AZ Front axle support to adapter E46 / Four Replace screws 110 Nm
Wheel Drive
12AZ Heat shield to front axle carrier E60, E61, E63, 8 Nm
E64, E65, E66,
E67
13AZ Mounting bracket to front axle E60 / Four M8 x 26 19 Nm
carrier / engine carrier Wheel Drive,
E61 / Four
Wheel Drive
31 12 Axle guide and axle strut
Tightening Torques
specifications
1AZ Tension strut to front axle E12, E24 / to Tighten in normal 80 Nm
support 5.82 position.
E23 Tighten in normal 135 Nm

position.
E39, E52 Tighten in normal 110 Nm
position.
E53 Replace screw. 165 Nm
Tighten in normal
position.
E60, E61, E63, M12 10.9 Replace bolt and nut.
E64, E65, E66, Tighten in normal
E67 position.
E83 Replace screw.
Tighten in normal
position.
2AZ Wishbone to front axle support E24 / from 5.82, tighten in normal position 77,5 Nm
E28, E31, E32,
E34, E38, E39 /
8 Cylinder
E39 / Tighten in normal 110 Nm
6 Cylinder, E52 position.
E12, E21, E23, Tighten in normal 85 Nm
E24 / to 5.82 position.
E53, E60, E61, M12 10.9 Replace bolt and nut.
E66, E67, E83 position.
Angle of rotation 90±15 °
3AZ Wishbone (ball joint) to front E30 Replace nut. 85 Nm
axle support
E36, E46 Replace nut. 90 Nm
E30 / 4WD Replace nut. 100 Nm
E85, E86 M14x1,5 Replace nut. 80 Nm
4AZ Wishbone to spring strut E21, E30 65 Nm
5AZ Wishbone to swivel E30 / 4WD 85 Nm

bearing/spring strut
E30 / 4WD Polystop nut 93 Nm
E34 / 4WD 80 Nm
6AZ Wishbone to swivel E36, E46, E85, Use of impact wrench 65 Nm
bearing/steering knuckle E86 not permitted!
Replace nut.
E38 Replace nut. 93 Nm
E39, E53, E52, Replace nut. 80 Nm
E83, E60 /
4WD, E61 /
4WD, E67
E60 / Rear end, Replace nut. 165 Nm
E61 / Rear end,
E63, E64, E65,
E66
7AZ Bracket for wishbone to engine E30 42 Nm

support
E36 47 Nm
E46 Replace screws. 59 Nm
E85, E86 M10 10.9 Replace screws. 56 Nm
8AZ Ball joint for wishbone to front E34 / 4WD, E46 77 Nm
axle support / 4WD
9AZ Wishbone to ball joint E34 / 4WD, E46 80 Nm

/ 4WD
10AZ Wishbone mount to front axle E34 / 4WD 47 Nm
support
E46 / 4WD Replace screws. 59 Nm
11AZ Compression strut to body E24 / from 5.82, Tighten in normal 130 Nm
E28 position.
12AZ Compression strut to track- E24, E28 / from 93 Nm
rod arm/steering 5.82, E31, E32,
knuckle/swivel bearing E34, E38
E39 80 Nm
13AZ Compression strut to E31, E32, E34, Tighten in normal 127 Nm
connecting pipe/front axle E38, E39 position.
support
14AZ Compression strut to cross E31 Tighten in normal 127 Nm

reinforcement position.
15AZ Connecting pipe to body E31, E32, E34 127 Nm
16AZ Support for connecting pipe to E31, E32, E34 59 Nm

body
17AZ Connecting pipe to E24 / from 5.82, 60 Nm

compression strut bearing E28
18AZ Tension strut on the track-rod E23 85 Nm

arm
19AZ Tension strut to steering E39, E52, E67 80 Nm

knuckle/swivel bearing
E60 / Rear end, 165 Nm
E61 / Rear end,
E63, E64, E65,
E66
20AZ Tension strut to guide joint E53, E83 Replace nut. 80 Nm
E60 / 4WD, E61 Replace nut. 165 Nm

/ 4WD
21AZ Guide joint to swivel bearing E53, E60 / Replace screws. 60 Nm
4WD, E61 /
4WD, E83
31 21 Wheel Bearings and Steering Knuckle
Tightening Torques
specifications
1AZ Collar nut (bearing unit) E24 / from 290 Nm
5.82, E28, E30,
E31, E32, E34,
E36, E38, E46,
E85, E86
E67 420 Nm
2AZ Drive flange to axle shaft E30 / 4WD, Replace collar nut. 250 Nm
E34 / 4WD
E46 / 4WD, Replace collar nut. 420 Nm
E53, E60 /
4WD, E61 /
4WD, E67, E83
3AZ Castle nut adjustmenting E12, E21, E23, Observe repair
instructions E24 / from 5.82 instructions.
4AZ Steering stub on spring strut E36 M12x20 Replace screws. 107 Nm
E36 Shoulder 107 Nm

screw
M12x42
E39 Bolt with 81 Nm
flange
M12x1.5x95
E38, E46, E85, M12 Replace screw. 81 Nm
E86, E60, E61,
E63, E64
5AZ Bearing unit on swivel bearing E39, E52, E60 / Replace screws. 110 Nm
Rear end, E61
/ Rear end,
E63, E64, E65,
E66
Drive flange to front axle shaft
Collar nut 420Nm

Replace collar nut.
31 31 Spring Struts
Tightening Torques
1AZ Spring strut support bearing / E60, E61, E63, Flanged Replace nuts 34 Nm
adapter for rough road E64, E65, E66, hexagon nut
package to wheel arch / E67, E83, E85,
adapter for rough road E86
package
E28, E30, E31, Hexagon Replace nuts 24 Nm
E32, E34, E36 / flange nut
S50 / S52, E38, dia. 18 mm
E39
E36 / S50 / S52 Flanged Replace nuts and secure 27 Nm
hexagon nut with Loctite 242
dia. 21 mm
E32, E34, E36, Flanged Replace nuts 34 Nm
E46, E53 hexagon nut
dia. 21 mm
E52 Hexagon Replace nuts 28 Nm
flange nut
dia. 18 mm
2AZ Shock absorber piston rod on E12, E21, E23, 80 Nm
thrust bearing E24 / until 5.82
E24 / from 5.82, M12 (with 64 Nm

E30, E31, E32, external
E34 hexagon
piston rod)
E24 / from 5.82, M12 (with 44 Nm
E30, E31, E32, internal
E34 hexagon
piston rod)
E36, E38, E39, Replace nut 64 Nm
E46, E52, E53,
E60, E61, E63,
E64, E65, E66,
E67, E83, E85,
E86
3AZ Spring strut shock absorber to E34 / Four 80 Nm
pivot mount Wheel Drive
E53 Replace screw & nut 250 Nm

E52, E60 / Replace screw & nut 81 Nm
except AWD,
E61 / except
AWD, E63,
E64, E65, E66
E60 / Four Replace screw & nut 100 Nm
Wheel Drive,
E61 / Four
Wheel Drive,
E67, E83
31 35 Stabilizer Bar
Tightening Torques
specification
1AZ Retaining bar for stabilizer to E21 50 Nm
front axle carrier / body
E12, E24 / until 45 Nm
5.82
E36, E46, E39, M8 tighten in normal position 21 Nm
E52, E85, E86
E65, E66, E67 Replace nuts 28 Nm
E60, E61, E63, Replace nuts 30.5 Nm
E64
E83 M10 10.9 56 Nm
2AZ Stabilizer to control arm E21 tighten in normal position 130 Nm
3AZ Stabilizer link to control arm and E23 M8 tighten in normal position 25 Nm
stabilizer
E23 M10 tighten in normal position 50 Nm
4AZ Stabilizer link to control arm E34 / Four 22 Nm
Wheel Drive
5AZ Stabilizer link to stabilizer E34 / Four 78 Nm
Wheel Drive
E38, E46, E83 65 Nm
E85, E86 M10 58 Nm
6AZ Stabilizer link on spring strut E28 (yellow 30 Nm
shock absorber and stabilizer chrome-
plated)
E24 / from (white 33 Nm
5.82, E28 / chrome-
from 5.82 plated)
E24 / from (yellow) (wrench surface on ball 59 Nm
5.82, E28, E31, head must be parallel to
E32, E34 absorber axle)
7AZ Stabilizer link on spring strut E36 59 Nm
shock absorber and stabilizer
(wrench surface on ball head
must be parallel to absorber
axle)
E30 / Four 47 Nm
Wheel Drive
E52 65 Nm
E53 100 Nm
8AZ Stabilizer link (with bracket) on E30 / Four 47 Nm
stabilizer Wheel Drive
9AZ Bracket for stabilizer link on E30, E36 42 Nm

control arm
10AZ Bracket for stabilizer link on E39, E60, E61, 59 Nm

swivel bearing E63, E64
11AZ Stabilizer link on E39, E60, E61, Replace nut 65 Nm

stabilizer/bracket E63, E64
12AZ Stabilizer link to stabilizer E65, E66, E67 Replace nut 58 Nm
13AZ Stabilizer link to spring strut E65, E66, E67 Replace nut
Torque angle 90 Â°
Anti-roll bar link to anti-roll bar
65Nm
Transmission oil
Technically suitable front axle transmission oils

Main group 31
32 00 Steering
Tightening Torques
1AZ Steering gear to front axle E21 50 Nm
carrier
E21 (power 41 Nm
steering)
E12, E23, E24 42 Nm
E24 / from 5.82, M12 80 Nm
E28, E31, E32,
E34
E28, E30, E36, M10 42 Nm
E46
E32/3 / 750iLs M10 10.9 110 Nm
E38 M10 8.8 Press steering gear 42 Nm
outwards to stop on front
axle support and first
tighten both front
screws.
E38 / Ball-and- M10 10.9 62 Nm
nut steering,
E39 / Ball-and-
nut steering
E39 / Rack-and- M10 Replace screws 42 Nm
pinion steering
gear, E52
E53 M12 10.9
Torque angle 90 °
E60 / REAR Replace screws & nuts
END, E61 /
REAR END,
E63, E64, E65,
E66, E67
Torque angle 90 °
E61 / Four M12 Replace screws & nuts 120 Nm
Wheel Drive,
E60 / Four
Wheel Drive
E83 M12 Replace screws & nuts 100 Nm
E85, E86 M10 Replace screws & nuts 42 Nm
2AZ Heat shield to steering gear E60, E61, E63, M6 7.5 Nm
E64
Ride height with vehicle load tolerance

Minimum value
min. - 20 mm
Maximum value
max. + 40 mm
Tolerance for ride height at design level

Tolerance for setpoint value
max. 2 mm
Difference between left and right
max. 2 mm
Tolerance for ride height in normal position

Tolerance for setpoint value
max. 10 mm
Difference between left and right
max. 10 mm
32 00 Steering
Tightening Torques
carrier
E21 (power 41 Nm
steering)
E12, E23, E24 42 Nm
E24 / from 5.82, M12 80 Nm
E28, E31, E32,
E34
E28, E30, E36, M10 42 Nm
E46
E32/3 / 750iLs M10 10.9 110 Nm
tighten both front
screws.
E38 / Ball-and- M10 10.9 62 Nm
nut steering,
E39 / Ball-and-
nut steering
pinion steering
gear, E52
E53 M12 10.9
Torque angle 90 °
END, E61 /
REAR END,
E63, E64, E65,
E66, E67
Torque angle 90 °
Wheel Drive,
E60 / Four
Wheel Drive
E64
32 00 Steering
Tightening Torques
carrier
E21 (power 41 Nm
steering)
E12, E23, E24 42 Nm
E24 / from 5.82, M12 80 Nm
E28, E31, E32,
E34
E28, E30, E36, M10 42 Nm
E46
E32/3 / 750iLs M10 10.9 110 Nm
tighten both front
screws.
E38 / Ball-and- M10 10.9 62 Nm
nut steering,
E39 / Ball-and-
nut steering
pinion steering
gear, E52
E53 M12 10.9
Torque angle 90 °
END, E61 /
REAR END,
E63, E64, E65,
E66, E67
Torque angle 90 °
Wheel Drive,
E60 / Four
Wheel Drive
E64
Steering shaft to steering gear
Recut thread. 22Nm
Renew clamping bolt.
Do not retorque with torque wrench.
32 21 Steering Arms
Tightening Torques
1AZ Tie rod to ball joint (castle nut) E21 60 Nm
2AZ Tie rod/axial joint to rack E21, E30 Replace retaining plate 75 Nm
E34, E36 Replace retaining plate 71 Nm

E39, E52 71 Nm
E46, E85 / 100 +10
except S54, Nm
E86 / except
S54
E53, E60, E61, 110 Nm
E63, E64, E65,
E66, E67, E83,
E85 / S54, E86
/ S54
3AZ Tie rod end to steering knuckle E34 / Four Replace nut 50 Nm
/ swivel bearing Wheel Drive
E36 Replace nut 36 Nm

E38, E39, E52 Replace nut 65 Nm
E46, E85, E86 Use of impact 65 Nm
screwdriver not
permitted!
Replace nut
E53, E60 / Four Replace nut 80 Nm
Wheel Drive,
E61 / Four
Wheel Drive,
E67, E83
E60 / REAR Replace nut 165 Nm
END, E61 /
REAR END,
E63, E64, E65,
E66
4AZ Tie rod clamping screw E38, E39 27 Nm
E12, E23, E24, 14 Nm

E28, E30, E31,
E32, E34
5AZ Tie rod end to tie rod (clamping E34 / Four 45 Nm
nut) Wheel Drive,
E36, E46, E85,
E86
E39, E52, E53, 51 Nm
E60, E61, E63,
E64, E65, E66,
E67, E83
6AZ Steering drop arm to steering E32, E34 / Four 59 Nm
gear Wheel Drive
E23 M26 Tightening value may be at least

exceeded up to correct 180 Nm
position to locking plate
E12, E23, E24, M22 Tightening value may be at least
E28 exceeded up to correct 140 Nm
position to locking plate
E31 70 Nm
E38, E39 Note direction of screw 61 Nm
thread.
In direction of travel: from
left on LHD or from right
on RHD vehicle
7AZ Steering guide arm to front axle E39 62 Nm

carrier
E23, E24, E28, M10 42 Nm
E31, E32, E34,
E38
E12, E23, E24 M12 85 Nm
8AZ Track rod arm to strut E12, E24 (up to Bolts secured with: Wire 55 Nm
5.82)
E23, E24 (from Bolts secured with: 62 Nm
5.82), E28 Loctite No. 270
Clean threads of tapped
bores and bolts.
E31, E32, E34 Bolts secured with: 110 Nm
Loctite No. 270
bores and bolts.
E30 / M3 Bolts secured with: 30 Nm
Loctite No. 270
bores and bolts.
9AZ Tie rod arm to control arm E12, E23, E24 66 Nm
(up to 5.82)
E30 / M3 66 Nm
E24 (from 93 Nm
5.82), E28,
E31, E32, E34
10AZ Leading strut to tie rod arm E23 93 Nm
11AZ Trailing strut to tie rod arm E31, E32, E34 93 Nm

Ear hose clamp gap dimension
Dimension [A]
max. 1 mm
32 31 Steering Column
Tightening Torques
specification
1AZ Universal joint/coupling to E12, E24 / until Replace clamping screw 25 Nm
steering gear/steering spindle 5.82
E21, E23, E24 / Recut thread 22 Nm

from 5.82, E28, Replace clamping screw
E30, E31, E32,
E34, E46, E52,
E60, E61, E63,
E64, E65, E66,
E67, E83
E36, E38, E39 Recut thread 19 Nm
Replace clamping screw
E53 / Steel M8 10.9 Recut thread 24 Nm
joint Replace clamping screw
E53 / Aluminium M8 10.9 Recut thread 28 Nm
joint Replace clamping screw
E85, E86 M8 Recut thread 30 Nm
Replace clamping screw
2AZ Bearing block for steering E31, E32, E34 M8 22 Nm
column adjustment to
instrument panel carrier and
pedal bearing block
3AZ Hexagon screw to bearing E12, E24 / until M10 x 115 25 Nm

block for steering column 5.82
adjustment
E28, E24 / from M8 x 110 22 Nm
5.82
E23 M10 x 170 27 Nm
E31, E32, E34 Observe repair
instruction.
E38, E39, E53 M8 Adjustment lever in 3.0 Nm
clamped position
E46, E83 M8 Value 1 4.0 Nm
Value 2 4.8 Nm
E85, E86 M8 Adjusting lever without 6 Nm
needle bearing
Adjusting lever with 3.2 Nm
needle bearing
4AZ Clamp/shackle for outer E12, E21, E24, 22 Nm
steering tube E28
E23 10 Nm
5AZ Airbag: Steering column to E23, E24, E28 18 Nm
holder
6AZ Steering column to instrument E60, E61, E63, 21 Nm

panel / support tube E64, E65, E66,
E67, E83, E85,
E86
7AZ Steering column to dashboard E12, E23, E24, 14 Nm
E28
8AZ Sliding piece (screw/nut) E46 9.5 Nm
9AZ Control unit, steering column E65, E66, E67 2.5 Nm
(CIM) to steering column
10AZ Bracket for sleeve to body E85, E86 M6 2.4 Nm
E83 M6 2.8 Nm
11AZ Cable holder to steering E46 M5 (silver) 8.8 Nm
column
E46 M5 (black) 4 Nm
12AZ Electric drive to steering E65, E66 M6 8 Nm
column
E60, E61, E63, 6 Nm
E64
13AZ Steering spindle to double E53, E65, E66, Recut thread 28 Nm
universal joint / universal joint E67, E83 Replace clamping screw
14AZ Universal joint with corrugated E65, E66, E67 Recut thread 22 Nm
tube to steering gear Replace clamping screw
15AZ Bearing block of steering E83 M8 Replace nuts 21.4 Nm

column to bulkhead
16AZ Steering column to bearing E83 M6 Stick in nut again 8.8 Nm

block
17AZ Steering spindle middle E60 / Four 6 Nm

section to assembly partition Wheel Drive,
wall E61 / Four
Wheel Drive
32 33 Steering Wheel
Tightening Torques
1AZ Steering wheel to steering E12, E21, E24, Nut 80 Nm
column E23, E28, E30
E31, E32, E34, Screw 62.5 Nm

E36, E38, E39,
E46, E52, E53,
E60, E61, E63,
E64, E65, E66,
E67, E83, E85,
E86
2AZ Retaining plate to steering E60, E61, E63, M5 6 Nm
wheel E64
3AZ Voltage regulator to steering E60, E61 M5x12 Replace screws 3 Nm

wheel
4AZ Engine electrics, Lane E60, E61 M5x12 Replace screws 4 Nm

Departure Warning, to steering
wheel
32 34 Airbag and airbag steering wheel
Tightening Torques
1AZ Airbag unit to steering wheel E23 / E24 / Airbag unit I 8 Nm
E28 / E30 /
E31 / E32 / E34
E36 / E38 / Airbag unit II 2 Nm
E39 / E46
E53 / E83 M6 8 Nm
32 41 Pump and Oil Supply
Tightening Torques
specification
1AZ Power steering pump / bearing E39 / M5 Observe tightening 25 Nm
block of power steering pump sequence
to crankcase / oil sump / oil filter
unit carrier / A/C compressor
carrier
E36, E38, E39, Note shims, refer also to 21 Nm
E46, E52, E53 Service Information Gr.
32
M47T2 / M6 8 Nm
M57TU /
M57T2
N62 / N62TU / M8 Replace nuts 21 Nm
N73
N52 / N52K / M10 x 33 Replace aluminium
N53 screws/bolts
Follow repair instruction .
Torque angle 90 째
N54 M10 Follow repair instruction . 38 Nm
E60, E61, E63, M8 21 Nm
E64, E65, E66,
E67, E83, E85 /
S54, E86 / S54
2AZ Pump bracket on engine E38 / M60/1 / 22 Nm
support M60/2 / M62,
E39 / M62
3AZ Hydraulic line connections to E38 Banjo bolt Replace sealing rings 33 Nm
vane pump/power steering M12
pump and steering gear/banjo
bolts, steering hydraulics
E36, E39, E46, Banjo bolt Replace sealing rings 35 Nm
E52 M14
E38 Banjo bolt Replace sealing rings 39 Nm
M14
E60, E61, E63, M14 non- Replace sealing rings 35 Nm
E64 return valve
E63, E64, E65, M14
E66, E85 / S54,
E86 / S54
E46, E52, E53 M16
E64, E65, E66, M16
E83, E85 / S54,
E86 / S54
E38, E53 Banjo bolt Replace sealing rings 45 Nm
M18
E36, E38, E39, Cap screw Replace sealing ring 36 Nm
E46, E53, E60,
E61, E63, E64,
E83
E65, E66, E67 Cap screw Replace sealing ring 39 Nm
4AZ Hydraulic line connections to E31, E32, E34 40 Nm
DS controller
5AZ Mounting of hydraulic line E60, E61, E63, M6 Screw, nut or rubber- 7.5 Nm
E64, E65, E66, metal body
E67
E60, E61, E65, M8 Screw, nut or rubber- 19 Nm
E66, E67 metal body
E83, E85 / S54, M6 Screw, nut or rubber- 8 Nm
E86 / S54 metal body
6AZ Holder, expansion hose, to E60, E61, E63, M6 8.8 7.5 Nm
vane pump / power steering E64, E65, E66
pump
E65 / M67 M8-8 19 Nm
7AZ Mounting hydraulic pump to E65 3 Nm
engine block / oil sump
9AZ Oil reservoir to holder E60, E61, E63, M6 6 Nm

E64
E65, E66, E67, M6 4 Nm
E83
E85 / S54, E86 M6 5.5 Nm
/ S54
10AZ Expansion hose part 1 to part E60, E61, E63, 30 Nm
2 E64, E65, E66
11AZ Expansion hose mounting E60 M6 10 Nm
12AZ Line fastening steering E60 M6 7.5 Nm

hydraulics
E60 M8 19 Nm
13AZ Oil tank holder to body E83 M8 19 Nm
14AZ Belt pulley to power steering E60, E61, E63, M8 8.8 22 Nm

pump E64, E65, E66,
E67
E39, E46, E53, M8 10.9 27 Nm
E65, E66, E67
E83 / M54 / M8 28 Nm
N46
E83 / M57TU / M8 22 Nm
M57T2 /
M47T2, E85 /
S54, E86 / S54
15AZ Bracket, pressure line, E65 / M57TU / 19 Nm
Dynamic Drive, to oil sump M57T2, E66 /
M57T2
16AZ Bracket, pressure line, to E60, E61, E63, M8 19 Nm
steering gear E64
17AZ Bracket, hydraulic line, to E60, E61, E63, M6 12 Nm

stabilizer bar mounting E64
18AZ Bracket, power steering E63 / N52, E64 M10 Replace aluminium
pump, to crankcase / N52 screws/bolts
Torque angle 90 째
19AZ
20AZ Power steering pump to water E46 / N40 / N42 M8 32 Nm

pump / N45 / N46,
E60 / N46T
E83 / N46 M8 28 Nm
21AZ Bracket, pressure line (ARS), E63 / N52, E64 M10 Replace aluminium
to crankcase / N52 screws/bolts
Torque angle 90 째
E60 / N52, E61 M8x17.5 Replace aluminium
/ N52, E63 / screw/bolt
N52, E64 / N52,
E65 / N52, E66
/ N52
Torque angle 45 째
22AZ Pressure line to power E85 / S54, E86 M14 Replace sealing rings 33 Nm
steering gear / S54
23AZ Return line to power steering E85 / S54, E86 M16 Replace sealing rings 35 Nm
gear / S54
Lubricating grease FB-1 100 g, 83 23 2 208 093

Tube
33 11 Rear Differential Case with Cover
Tightening Torques
1AZ Case Covers E36 / E38 / M10 8.8 168N 45 Nm
E39 / E46 / 168K
Transmission allocation E53 / E60 /
E61 / E65 / 188
E66 / E83 / 188N
E85 / E86 188K
210
210N
215
E46 / E83 / E85 M10 10.9 168K 55 Nm
E38 / E39 / M10 10.9 188K 55 Nm
E46 / E53 /
E60 / E61 /
E65 / E66 /
E83 / E85
E46 / E53 / M10 215K 90 Nm
E60 / E61 /
E63 / E64 /
E65 / E66 /
E67 / E83
E38 / E39 / E52 M10x25 10.9 220K 90 Nm
E38 / E39 / E52 M10x75 10.9 220K 110 Nm
E38 / E39 / E52 M10x67 10.9 220K 130 Nm
E65 / E66 / E67 M10 230K 90 Nm
E85 M10 10.9 168L 55 Nm
E60 / E61 / M10 10.9 188L 55 Nm
E63 / E64 188LW
E65 / E66 / M10 10.9 188L 55 Nm
E83 / E85 / E86
E60 / E63 / E64 M10 10.9 215 with lock 60 Nm
2AZ Side bearing cap (insert into E12 / E21 / M8 Type M, G 22 Nm
through bore-holes only new E23 / E24 /
coated screws or screws with E28 / E30 /
Loctite 270) E31 / E32 /
E34 / E36 / E38
E12 / E21 / M8 Type K
E28 / E30 /
E34 / E36 /
E38 / E39
Torque angle 40 °
3AZ Oil fill and drain plug E30 / E31 / Replace sealing ring 65 Nm
E32 / E34 /
with sealing ring E36 / E38 /
E39 / E46 /
E52 / E53 /
E60 / E63 /
E83 / E85 / E86
4AZ Drive flange, right E34 / 525ix M10 59 Nm
5AZ Drive flange, left E34 / 525ix M14 x 1.5 Jointing torque 90 Nm
(always replace screws)
Torque angle 100 + 4 °

6AZ Oil cooler connection to rear E31 35 Nm
differential
7AZ Union nuts pipe oil cooler E31 17 Nm
8AZ Vibration damper on bracket E38 / E39 / E46 77 Nm
9AZ Oil filler and oil drain plugs with E30 / E31 / Replace oil filler and oil 60 Nm
O-ring on cover / housing E32 / E34 / drain plugs
E36 / E38 /
E39 / E46 /
E52 / E53 /
E60 / E61 /
E63 / E64 /
E65 / E66 /
E67 / E83 /
E85 / E86
33 17 Rear axle differential mountings
Tightening Torques
specifications
1AZ Rear axle final drive to rear E21 90 Nm
axle support
E12, E24 / to 80 Nm
5.82
E23, E24 / from 110 Nm
5.82, E28 / from
5.82, E30, E32,
E34, E36 / Z3 /
compact
E36, E46 Front 95 Nm
E46 / S54, E85 / Front Observe repair 200 Nm
S54, E86 / S54 instructions.
E38, E39, E52 Front 150 Nm
E53, E60, E61, Front Observe repair 100 Nm
E63, E64, E65, instructions.
E66, E67, E83,
E85 / except
S54, E86 /
except S54
E31, E36 Rear 77 Nm
E38 Rear 102 Nm
E38 Rear also tighten via screw 75 Nm
head
head
E46 / Rear 174 Nm
exceptS54
E46 / S54, E85 / Rear Observe repair
S54, E86 / S54 instructions.
Angle of rotation 90 Â°
head
E53, E60 / Rear Observe repair 165 Nm
exceptS85, instructions.
E61, E63 /
exceptS85,
E64, E65, E66,
E67, E83, E85 /
exceptS54, E86
/ exceptS54
E60 / S85, E63 / Rear Observe repair 220 Nm
S85 instructions.
2AZ Rear axle differential to anti-roll E21, E30 90 Nm
bar link and anti-roll bar link to
body
3AZ Rear axle differential to rubber E12, E23, E24, 87 Nm

mount E28
E32, E34 77 Nm
4AZ Rear axle differential lid with E30, E36 / Z3 / 77 Nm
rubber mount to body compact
5AZ Rear axle differential holder to E32 M12 8.8 81 Nm

housing cover
E32, E34 M12 10.9 102 Nm
6AZ Rubber mount to body E12, E24 48 Nm
E23 M8 8.8 Thread, oil and grease 24 Nm

free
Screw lock with Loctite
270
E23 M8 10.9 Thread, oil and grease 37 Nm
free
270
E23, E32 M10 8.8 Thread, oil and grease 52 Nm
free
270
7AZ Rear axle differential holder to E31 M14 x 1.5 186 Nm
rear axle differential
8AZ Rear axle differential holder to E31 127 Nm

rear axle support
9AZ Vibration absorber E65 / M57TU / M12 100 Nm

M57T2
33 21 Output Shaft
Tightening Torques
1AZ Output shaft to rear axle
differential and drive flange
Hexagon socket screw E30, E32, E34 M10x50 10.9 Replace screws 60 Nm
Torx screw without ribbed teeth E30, E31, E32, M10x50 10.9 Replace screws 60 Nm
E34, E36, E38 (black)
Torx screw with ribbed teeth E36, E39, E46 M8x40 Replace screws 64 Nm
(black)
E36, E39, E46, M8x40 Replace screws 52 Nm
E60, E83, E85 (silver)
E36 / M54 / Z3 M10x23 10.9 Replace screws 85 Nm
3.0i, E46 (silver)
E30, E36, E38, M10 (silver) Replace screws 80 Nm
E39, E46, E52,
E53, E60, E61,
E63, E64, E65,
E66, E83, E85,
E86
E36 / Z3 2.8i, M10x46 10.9 Replace screws 100 Nm
E36 / S50 / S52 (black)
/ S54, E46 /
S54, E85 / S54,
E86 / S54
E31, E38, E39, M12x50 10.9 Replace screws 135 Nm
E60, E63, E64 (black)
33 31 Rear axle carrier
Tightening Torques
1AZ Vibration damper to rear axle E36 / E38 / M12 77 Nm
carrier E46 / E83
E65 / E66 / E67 M12 100 Nm

33 32 Axle guide and axle strut
Tightening Torques
specifications
1AZ Trailing arm to rear axle support E34 (M5) Replace screw. 55 Nm
Tighten using special
tool 33 3 060 and Hazet
6291-2CT torque
wrench.
E36 position.
E30, E32, E34, 10.9 77 Nm
E36
2AZ Trailing arm to body E31 M14 x 1.5 127 Nm
3AZ Trailing arm to wheel carrier E31 M18 x 1.5 278 Nm
4AZ Control arm to wheel carrier E31 The taper spigot and 80 Nm
bore hole must be free
of grease.
E38, E52 M10 65 Nm
E39 The taper spigot and 55 Nm
bore hole must be free
of grease.
E53 56 Nm
E60, E61, E63, M10 Replace nut. 65 Nm
E64, E65, E66,
E67
E60, E63, E64, M12 Replace nut. 108 Nm
E65, E66
5AZ Control arm to rear axle E31 Tighten in normal 95 Nm
support position.

position.
position.
With torque wrench
Hazet 6290-CT
position.
position.
with special tool 32 3 150
and torque wrench
Hazet 6291-ICT
E67 position.
6AZ Engine support arm to rear axle E31 M14 x 1.5 127 Nm
support
7AZ Engine support arm to wheel E31 150 Nm

carrier
8AZ Upper wishbone to wheel E31 M14 x 1.5 127 Nm

carrier
E38, E52 160 Nm
E39 142 Nm
E64, E65, E66
9AZ Integral link to trailing arm E31 M16 x 1.5 Tapered spigot and bore 120 Nm
both free of grease
10AZ Integral link to upper wishbone E31 M14 x 1.5 127 Nm
11AZ Upper/lower wishbones to E36, E46 M12 x 1.5 Replace nut. 110 Nm
trailing arm Tighten in normal
position.
12AZ Trailing arm to bearing support E36, E46 110 Nm
E83, E85, E86 M12 x 1.5 100 Nm

10.9
13AZ Trailing arm bearing support to E36, E46, E83, 77 Nm
body E85, E86
14AZ Upper wishbone to rear axle E31 M12 x 1.5 Tighten in normal 77 Nm
carrier position.
E36 M12 10.9 Tighten in normal 77 Nm

position.
Always replace reduced-
shaft bolts with multi-
purpose bolts and
washers, (see BMW
Group Parts).
E38, E39, E52 Tighten in normal 110 Nm
position.
position.
E86 position.
E63, E64 Tighten in normal
position.
E65, E66, E67 Replace nut.
Tighten in normal
position.
15AZ Lower wishbone to rear axle E36 M12 10.9 Tighten in normal 77 Nm
carrier position.
Always replace reduced-
shaft bolts with multi-
purpose bolts and
washers, (see BMW
Group Parts).
E86 position.
16AZ Support bracket on body E21 / E30 28 Nm
17AZ Compression strut on body E46, E83, E85, M8 8.8 21 Nm

E86
E30, E32, E34, M8 10.9 30 Nm
E36, E85, E86
E60, E61, E63, M10 10.9 48 Nm
E64
E65, E66, E67 M10 10.9 38 Nm
18AZ Auxiliary control arm to trailing E32, E34 M14 x 1.5 Tighten in normal 127 Nm
arm and rear axle support position.
19AZ Additional strut on rear axle E32, E34 M12 x 1.5 110 Nm
support
20AZ Swinging arm to rear axle E38 Front Tighten in normal 60 Nm

support position.
E39 Front Tighten in normal 58 Nm

position.
E52 Front Tighten in normal 105 Nm
position.
E53, E60, E61, Front Replace nut. 100 Nm
E66, E67 position.
E38 Rear Tighten in normal 130 Nm
position.
E39 Rear M12 Tighten in normal 115 Nm
position.
E39 / Touring, Rear M14 Tighten in normal 174 Nm
M5 position.
E52 Rear M14 Tighten in normal 160 Nm
position.
E53, E60, E61, Rear M14 Replace nut. 175 Nm
E66, E67 position.
21AZ Integral link on front wheel E38, E39, E52, Tighten in normal 105 Nm
support E53 position.

E64, E65, E66, position.
E67
22AZ Screw connection, swinging E38 Tighten in normal 236 Nm
arm, integral link, wheel carrier position.
E39, E52 Replace nut. 256 Nm

Tighten in normal
position.
Tighten in normal
position.
E67 position.
23AZ Bracing strut to compression E46 / M3 / M3 Replace screws.
strut / body CSL
24AZ Upper wishbone to trailing arm E85, E86 M12x1.5 8.8 Replace nut. 100 Nm
E83 M12x1.5 Replace nut. 106 Nm

25AZ Lower wishbone to trailing arm E85, E86 M12x1.5 10.9 Replace nut. 77 Nm
Tighten in normal
position.
E83 M12x1.5 10.9 Replace nut. 100 Nm
Tighten in normal
position.
26AZ Tension strut to compression E83 M10 60 Nm
strut / body
27AZ Heat shield to compression E83, E85, E86 M6 5 Nm

strut
28AZ Heat shield to compression E65, E66, E67 M8 19 Nm

strut
33 31 Rear axle carrier
Tightening Torques
1AZ Vibration damper to rear axle E36 / E38 / M12 77 Nm
carrier E46 / E83
E65 / E66 / E67 M12 100 Nm

33 33 Rear Axle Suspension
Tightening Torques
specifications
1AZ Rubber mount to rear axle E21, E23 95 Nm
support
E21, E24, E28 40 Nm
2AZ Threaded bolt to body E36 120 Nm
E36 / Z3 / 127 Nm
compact
E46, E85, E86 90 Nm
3AZ Rear axle support with rubber E36, E46, E83, M12 x 1.5 77 Nm
mounts to body E85, E86
E36 M14 x 1.5 140 Nm

E38 127 Nm
E39, E52, E53 163 Nm
E60, E61, E63, 165 Nm
E64, E65, E66,
E67
4AZ Rear rubber mount to body E32, E34 M10 Thread, oil and grease 45 Nm
free,
270
5AZ Rear axle support to rear E32, E34 M12 77 Nm
rubber mount
6AZ Fixing the rubber mount/right E67 8 Nm

rear axle support
33 41 Wheel Bearings
Tightening Torques
1AZ Rear axle shaft to drive flange E12 / E21 / Collar nut Replace collar nut 435 Nm
E23 / E24 yellow
chromated
E28 Collar nut Replace collar nut 190 Nm
waxed white
M22
E23 / E24 / Collar nut Replace collar nut 250 Nm
E28 / E32 / E34 waxed white
M27
2AZ Bearing unit on wheel carrier E39 Replace screws
Torque angle 90 °
E60 Replace screws
Torque angle 90 °
E53 / E61 / 100 Nm
E63 / E64 /
E65 / E66
3AZ Drive flange to axle shaft E53 / E61 / M27 Replacing collar nut and 420 Nm
E63 / E64 / lightly oil contact face
E65 / E66 / E67
E31 / E36 / M27 Replacing collar nut and 300 Nm
E38 / E39 / lightly oil contact face
E46 / E52 /
E60 / E83 /
E85 / E86
E36 / E46 / M24 Replacing collar nut and 250 Nm
E85 / E86 lightly oil contact face
E30 / E36 M22 Replacing collar nut and 200 Nm
lightly oil contact face
33 52 Shock Absorbers
Tightening Torques
1AZ Shock absorber to trailing arm/ E12, E23, E24, 127 Nm
wheel carrier/ swinging arm/ E28, E32, E34,
support arm/ control arm E38, E52
(tighten in normal position)
E21 54 Nm
E30, E36/7, 77 Nm
E36/5
E31 115 Nm
E36, E46, E83, M12 100 Nm
E85, E86
E39, E53 M14 Replace nut 127 Nm
E60, E61, E63, M14 Replace screw 165 Nm
E64, E65, E66
E67 M16 Replace screw 250 Nm
2AZ Shock absorber piston rod on E21, E30 15 Nm
thrust bearing
E23, E24, E28, 25 Nm
E34
E36, E46, E83 M10 Replace nut 14 Nm
E38, E39, E52 M10 Replace nut 23 Nm
E38, E39 M14 Replace nut 27 Nm
E53, E60, E63, M12 Replace nut 27 Nm
E64, E65, E66,
E67
E61 M12 Replace nut 28 Nm
E85, E86 M10 x 1 Replace nut 13 Nm
3AZ Support on body/rear axle E36, E38 M8 Replace nut 24 Nm
carrier
E39 Nut and bolt Replace nut 24 Nm
yellow
chrome-
plated
E39 Nut and bolt Replace nut 28 Nm
silver-grey
E46, E52, E60, M8 Replace nuts 28 Nm
E63, E64, E65,
E66, E67
E53 M10 Replace nuts 56 Nm
E83, E85 / S54, M8 Replace nuts 24 Nm
E86 / S54
E85 / except M8 Replace nuts 27 Nm
S54, E86 /
except S54
33 55 Anti-roll bar
Tightening Torques
specifications
1AZ Anti-roll bar to trailing arm E30, E31, E36 / M8 tighten in normal position 22 Nm
Z3 / compact
E31 M10 tighten in normal position 42 Nm
2AZ Anti-roll bar link on anti-roll E38 42 Nm
bar/swinging arm
E39, E52 65 Nm
E53 100 Nm
E60, E61, E63, M10 65 Nm
E64
E65, E66, E67 M10 58 Nm
E60, E61, E63, M12 100 Nm
E64, E65, E66,
E67
3AZ Retaining bracket, anti-roll bar E46, E52, E85, 22 Nm
to rear axle support E86
E53 19 Nm
E60, E61, E63, M8 28 Nm
E64
E65, E66, E67 M10 60 Nm
E83 M8 21 Nm
4AZ Anti-roll bar link to bracket E46, E85, E86 M8 Replace nut 22 Nm
5AZ Anti-roll bar link holder to top E46, E85, E86 M8 Replace nuts 22 Nm
wishbone
6AZ Vibration absorber to retaining E61 M12 100 Nm

bracket of right anti-roll bar
7AZ Anti-roll bar link to anti-roll bar / E83 M10 Replace nuts 65 Nm
top wishbone
Transmission oil
Hypoid Axle Oil G4 500 ml, 83222447362

Bottle
Transmission oil

Bottle
Transmission oil
Rear axle differential oil SAF-XJ Booster 3x 1 l, 83222282583

Bottle
Transmission oil
Rear axle differential oil SAF Carbon Mod 500 ml, 83120445832
Bottle
Transmission oil

Bottle
Transmission oil
Technically suitable rear axle differential oils

Main group 33
Transmission oil
BMW Synthetics OSP 1 l, 83222365987

Bottle
60 l, 83229407768
Barrel
Transmission oil
BMW HOC oil 850 ml, 83222413513

Bottle
Transmission oil
Rear axle differential oil MSP/A 1 l, 83222365988

* TU = Trade Unit. TU numbers cannot be ordered! Bottle
1000 ml, 83229405462
TU*
34 00 Testing and bleeding brakes
Tightening Torques
1AZ Vent valve E39 / E38 / Width across flats 7 3,5-5,0
E46 / E52 / Nm
E53 / E83 /
E85 / E86 /
E65 / E66 /
E67 / E60 /
E61 / E63 / E64
Width across flats 9 7-11 Nm
Width across flats 11 12-16 Nm
34 11 Front Brake
Tightening Torques
1AZ Brake disk to wheel hub E36 / E39 / Replace screws 16 Nm
(contact faces between brake E38 / E46 /
disk and wheel hub cleaned E52 / E53 /
and grease-free) E85 / E86 /
E83 / E65 /
E66 / E67 /
E60 / E61 /
E63 / E64
2AZ Brake caliper to steering E34 / E36 / Replace self-locking or 110 Nm
knuckle E32 / E31 / microencapsulated
E38 / E39 / screws
(screws lightly oiled, contact E46 / E52 /
surfaces between brake E53 / E65, E30
caliper and steering knuckle / 325iX, E66 /
cleaned and grease-free) E67 / E83 /
E85 / E86 /
E60 / E61 /
E63 / E64
2AZ with aluminium brake caliper E31 Replace self-locking or 115 Nm
microencapsulated
screws
E12 / E21 / Replace self-locking or 95 Nm
E23 / E24 to microencapsulated
5.82 screws
E28 / E30 / E24 Replace self-locking or 123 Nm
/ from 5.82 microencapsulated
screws
3AZ Guide bolt E36 / E39 / wrench size Replace self-locking or 30 - 5 Nm
E38 / E46 / 7 mm microencapsulated
E52 / E53 / screws
E85 / E86 /
E83 / E65 /
E66 / E67 /
E60 / E61 /
E63 / E64
4AZ Bolts to guide pin (always E30 35 Nm
replace)
5AZ Protective plate to steering E85 / E86 / E83 M6 Replace self-locking or 9 Nm

knuckle microencapsulated
screws
E67 / E60 / M6 Replace self-locking or 12 Nm
E61 / E63 / microencapsulated
E64 / E65 / E66 screws
34 21 Rear Brake
Tightening Torques
specifications
1AZ Brake drum/disc on wheel hub E39 / E38 / Replace screws 16 Nm
E46 / E52 /
E53 / E83 /
E85 / E86 /
E65 / E66 /
E67 / E60 /
E61 / E63 / E64
2AZ Wheel brake cylinder on brake E36 Replace self-locking or 10 Nm
anchor plate microencapsulated
screws
3AZ Brake anchor plate on trailing E65 / E66 / M12 Replace self-locking or 110 Nm
arm/wheel carrier E67 / E60 / microencapsulated
E61 / E63 / E64 screws
E38 / E39 / screws
E46 / E53 /
E85 / E86
E83 M10 Replace self-locking or 65 Nm
microencapsulated
screws
5AZ Guide bolt E36 / E39 / WAF 7 Replace self-locking or 30 - 5 Nm
E52 / E53 / screws
E83 / E85 /
E86 / E65 /
E66 / E67 /
E60 / E61 /
E63 / E64
6AZ Protective plate to wheel E85 / E86 / E83 M6 Replace self-locking or 9 Nm
carrier microencapsulated
screws
E85 / E86 / E83 M8 Replace self-locking or 15 Nm
microencapsulated
screws
E64 / E65 / screws
E66 / E67
34 31 Brake Master Cylinder
Tightening Torques
1AZ Brake master cylinder to brake E30 24 Nm
booster (vacuum)
E32 Replace self-locking nut. 21 Nm
E28 / E34 / Replace self-locking nut. 26 Nm
E36 / E46 /
E38 / E39 /
E52 / E53 /
E85 / E86 / E83
E65 / E66 / Replace self-locking nut. 26 Nm
E60 / E61 / Retighten after 30
E63 / E64 minutes.
2AZ Brake master cylinder to brake E31 / E32 / Replace hexagon socket 28 Nm
booster hydraulic E34 / E24 head screw with a
hexagon screw, refer to
BMW Parts Service
3AZ Expansion tank to brake E36 / E46 / 3,5 Nm
master cylinder E85 / E86
E83 / E60 / 8 Â±2 Nm

E61 / E63 / E64
34 32 Brake Lines
Tightening Torques
specifications
1AZ Retaining screws / Brake E36 / E38 / E39 M10 x 1 18 Nm
hoses
E53 / E83 M10 x 1 14 Nm
E60 / E61 / M10 x 1 14 Nm
E63 / E64 /
E65 / E66 /
E67 / E85 /
E86 / E46
E60 / E61 / M10 x 1 Blue union screw 16 Nm
E63 / E64 / connection in steel e.g.
E85 / E86 / E46 brake hose
E63 / E64 / connection in aluminium
E85 / E86 / E46 e.g. hydraulic control unit
E36 / E38 / E39 M12 x 1 18 Nm
E53 / E83 M12 x 1 14 Nm
E63 / E64 / connection in steel e.g.
E85 / E86 / E46 brake hose
E63 / E64 / connection in aluminium
E85 / E86 / E46 e.g. hydraulic control unit
2AZ Brake hose to brake caliper, E85 / E83 / 19 Nm
front and rear E86 / E46
3AZ Bracket to trailing arm E85 / E86 / E83 M6 9 Nm
E85 / E86 M5 5 Nm
4AZ Brake hose to brake caliper, E53 / E60 / M10 x 1 24 Nm
front E61 / E63 /
E64 / E65 /
E66 / E67
5AZ Brake hose to brake caliper, E53 Banjo bolt 40 Nm
rear M10x1
E60 / E61 / M10 x 1 24 Nm

E63 / E64 /
E65 / E66 / E67
6AZ Brake lines to hydraulic control E83 17 Nm
unit
34 33 Brake Booster
Tightening Torques
10AZ Hydraulic pipe to pressure E31 / E32 47 Nm
reservoir on power flow
regulator
11AZ Hydraulic pipe to pressure E31 / E32 40 Nm

reservoir
12AZ Brake booster to pedal E85 / E86 M8 Retighten 1x after 30 22 Nm

assembly console minutes on brake
booster
E36 / E46 25 Nm
E38 / E39 / 31 Nm
E52 / E53
E65 / E66 / Retighten 1x after 30 26 Nm
E67 / E60 / minutes on brake
E61 / E63 / booster
E64 / E83
34 41 Parking Brake
Tightening Torques
1AZ Handbrake lever to body E52 / E53 / 21 Nm
E60 / E61 /
E63 / E64
2AZ Housing cover to parking brake E65 / E66 / E67 2 Nm
3AZ Actuating unit and control unit E65 / E66 / E67 4 Nm

of parking brake
4AZ Mounting pan to tunnel E85 / E86 M6 8 Nm
5AZ Spring clip to wheel carrier E60 / E61 / M6 8 Nm

E63 / E64
6AZ Support Duo-Servo to wheel E60 / E61 / M10 60 Nm
carrier, rear E63 / E64
35 11 Pedal Assembly Console
Tightening Torques
1AZ Bearing pedestal to brake E38 / E39 / E52 31 Nm
assembly and body
E36 / E46 25 Nm
E53 / E65 / Retighten 1x on brake 21 Nm
E66 / E67 / booster after 30Â min.
E60 / E61 /
E63 / E64 / E83
E85 / E86 M8 Retighten 1x on brake 22 Nm
booster after 30 min
2AZ Bracket to bearing block E85 / E86 M6 9 Nm
34 51 Slip Control System (ABS, ASC+T, DSC)
Tightening Torques
specification
1AZ Control unit on hydraulic unit E46 (MK20) 2,6 Nm
E46 / E85 / E86 5+1 Nm

/ (MK60)
E38 / E39 / 2,9 Nm
E52 / E53 / E46
AWD / E65 /
E66 / E67
E60 / E61 / 3±0,3 Nm
E63 / E64 / E83
2AZ Pressure sensor ”V” and ”H” to E46 / E85 25 + 5 Nm
master brake cylinder
Pressure sensor to hydraulic unit E38 / E39 20 Nm
E52 / E53 / E46 Only with special tool 19 Nm

AWD / E65 / 34 1 290
E66
3AZ Rotation rate sensor / DSC E46 / E65 / 8 Nm
sensor to holder E66 / E67 /
E60 / E61 /
E63 / E64 /
E83 / E85 / E86
4AZ Bracket, rotation rate sensor to E46 / E85 / E86 8 Nm
body
5AZ Banjo bolt for pre-boost pump E46 20 Nm

intake line to pre-boost pump
6AZ Pulse generator to swivel E52 / E53 / 8 Nm

bearing/wheel carrier E46 / E85 /
E60 / E61 /
E63 / E64 / E67
E39 / E38 / 9 Nm
E65 / E66
7AZ Rotation rate sensor to body E38 / E39 8,6 Nm
8AZ Rotation rate sensor to body E52 / E53 8 Nm
9AZ Bracket to hydraulic unit E52 / E53 / 8 Nm

E46 / E85 /
E86 / E83 /
E60 / E61 /
E63 / E64
10AZ Bracket, hydraulic unit to body E52 / E53 / 8 Nm
E46 / E85 /
E86 / E83 /
E60 / E61 /
E63 / E64
11AZ All screws to precharging E52 / E53 / E46 M6 8 Nm
pump and holder (M3) / E65 /
E66
12AZ Pressure sensor, front and E60 / E61 / 25 + 5 Nm
rear for ACC, to brake line E63 / E64
34 51 Slip Control System (ABS, ASC+T, DSC)
Tightening Torques
specification
1AZ Control unit on hydraulic unit E46 (MK20) 2,6 Nm
E46 / E85 / E86 5+1 Nm

/ (MK60)
E38 / E39 / 2,9 Nm
E52 / E53 / E46
AWD / E65 /
E66 / E67
E60 / E61 / 3±0,3 Nm
E63 / E64 / E83
2AZ Pressure sensor ”V” and ”H” to E46 / E85 25 + 5 Nm
master brake cylinder
Pressure sensor to hydraulic unit E38 / E39 20 Nm
E52 / E53 / E46 Only with special tool 19 Nm

AWD / E65 / 34 1 290
E66
3AZ Rotation rate sensor / DSC E46 / E65 / 8 Nm
sensor to holder E66 / E67 /
E60 / E61 /
E63 / E64 /
E83 / E85 / E86
4AZ Bracket, rotation rate sensor to E46 / E85 / E86 8 Nm
body
5AZ Banjo bolt for pre-boost pump E46 20 Nm

intake line to pre-boost pump
6AZ Pulse generator to swivel E52 / E53 / 8 Nm

bearing/wheel carrier E46 / E85 /
E60 / E61 /
E63 / E64 / E67
E39 / E38 / 9 Nm
E65 / E66
7AZ Rotation rate sensor to body E38 / E39 8,6 Nm
8AZ Rotation rate sensor to body E52 / E53 8 Nm
9AZ Bracket to hydraulic unit E52 / E53 / 8 Nm

E46 / E85 /
E86 / E83 /
E60 / E61 /
E63 / E64
10AZ Bracket, hydraulic unit to body E52 / E53 / 8 Nm
E46 / E85 /
E86 / E83 /
E60 / E61 /
E63 / E64
11AZ All screws to precharging E52 / E53 / E46 M6 8 Nm
pump and holder (M3) / E65 /
E66
12AZ Pressure sensor, front and E60 / E61 / 25 + 5 Nm
rear for ACC, to brake line E63 / E64
Lubricating grease Staburags NBU 12K 100 g, 83 23 9 407 810

Tube
Safety cleaner 2.0 500 ml, 83192362037

Spray can
20 l, 83192362038
Canister
60 l, 83192362040
Canister
Brake block paste 3 g, 83192158851

* TU = Trade Unit. TU numbers cannot be ordered! Bag
100 g, 83192158852
Tube
5 g, 83230140233
TU*
Brake fluid DOT4, low viscosity 500 ml, 83130042718

OFF Can
30 , 83130430440
Barrel
Brake fluid DOT4, low viscosity 1, 83132406162

CHN Can
1, 83132467487
Can
Brake fluid DOT4 front left, low viscosity 250 ml, 83132405975
For invoicing purposes only. EU
500 ml, 83132405976
Can
1 l, 83132405977
Can
5 l, 83132405978
Can
30 l, 83130443028
Barrel
60 l, 83130443029
Barrel
1000 ml, 83132184842
TU*
1000 ml, 83132184843
TU*
1000 ml, 83130443030
TU*
Tightening Torques
assembly and body
E36 / E46 25 Nm
E60 / E61 /
E63 / E64 / E83
34 41 Parking Brake
Tightening Torques
1AZ Handbrake lever to body E52 / E53 / 21 Nm
E60 / E61 /
E63 / E64
2AZ Housing cover to parking brake E65 / E66 / E67 2 Nm
3AZ Actuating unit and control unit E65 / E66 / E67 4 Nm

of parking brake
4AZ Mounting pan to tunnel E85 / E86 M6 8 Nm
5AZ Spring clip to wheel carrier E60 / E61 / M6 8 Nm

E63 / E64
6AZ Support Duo-Servo to wheel E60 / E61 / M10 60 Nm
carrier, rear E63 / E64
Tightening Torques
assembly and body
E36 / E46 25 Nm
E60 / E61 /
E63 / E64 / E83
35 41 Accelerator Pedal and Linkage
Tightening Torques
1AZ Full-load stop E32 / E34 / 10 Nm
E36 / E38 /
E39 / E46
36 10 Wheels
Tightening Torques
specifications
1AZ Wheel bolt E30 / E31 / M12 - Screw in the wheel bolts 120 ± 10
E32 / E34 / and evenly tighten by Nm
E36 / E38 / hand in a crosswise
E39 / E46 / sequence in order to
E52 / E60 / centre the wheel rim.
E61 / E63 / - Tighten the wheel bolts
E64 / E85 / E86 to the specified
tightening toque in a
crosswise sequence
using a calibrated torque
wrench.
- Check all wheel bolts in
the same sequence and
retighten to the
prescribed tightening
torque if necessary.
E53 / E65 / M14 - Screw in the wheel bolts 140 ± 10
E66 / E67 / E83 and evenly tighten by Nm
hand in a crosswise
sequence in order to
centre the wheel rim.
- Tighten the wheel bolts
to the specified
tightening toque in a
crosswise sequence
using a calibrated torque
wrench.
- Check all wheel bolts in
the same sequence and
retighten to the
prescribed tightening
torque if necessary.
Wheel bolt
M14 140Nm
After installation, torque of all wheel bolts must be
checked again. Wheel bolts must not be oiled!
36 11 Wheel Rims
Tightening Torques
1AZ Wheel cover on disc wheel E31 / E32 / E34 9 Nm
Bolts coated with blue Loctite
No. 243
2AZ Valve on disc wheel (RDC) E38 / E39 / 3.5 Nm

E46 / E53 /
E65 / E66
3AZ Wheel electronics (RDC) on E38 / E39 / 3.5 Nm
valve E46 / E53 /
E65 / E66
Tyre-fitting paste 3500 g, 81220433046

Bucket
Lubricating spray 400 ml, 83192156562

Spray can
37 14 Electric Components
Tightening Torques
1AZ Wheel camber warning switch E32, E34 9 Nm
to console
2AZ Angled joint of jointed rod E32, E34 5 Nm
3AZ Hydraulic switch to distributor E24, E32 25 Nm
4AZ Hydraulic switch to hydraulic E24, E32 27 Nm

control unit
5AZ Solenoid valve to hydraulic E24, E32 55 Nm

control unit
6AZ Ride level sensor to holder E39, E38, E46, 5 Nm

E53, E52, E60,
E61, E63, E64,
E65, E66, E67,
E83, E85, E86
7AZ Control rod / jointed rod to ride E39, E46 9 Nm
height sensor / bracket / control
arm
E53, E60, E61, 8 Nm
E63, E64, E65,
E66, E67, E83,
E85, E86
E38 5 Nm
E52 10 Nm
8AZ Bracket ride level sensor to E85, E86 M6 8 Nm
front axle carrier
9AZ Control rod on transverse link E38, E83 8 Nm

(rear)
E52 10 Nm
10AZ Control rod to swinging arm E53, E60, E61, 8 Nm
(rear) E63, E64, E65,
E66
11AZ Bracket ride level sensor to E53, E60, E61, 8 Nm
rear axle carrier E63, E64, E65,
E66, E83, E85,
E86
12AZ Control lines for oscillating E60, E61, E63, 35 Nm
motor, rear, to valve block E64, E65, E66
13AZ Connecting nuts, hydraulic E60, E61, E63, 30 Nm

lines (pressure lines/control E64, E65, E66
lines)
14AZ Line holder / pipe holder / E60, E61, E63, 8 Nm

holder E64, E65, E66
15AZ Control lines for oscillating E60, E61, E63, 35 Nm

motor, front, to valve block E64, E65, E66
16AZ Pressure line DYNAMIC E60, E61, E63, 35 Nm

DRIVE circuit to valve block E64, E65, E66
17AZ Valve block to holder E60, E61, E63, 8 Nm

E64, E65, E66
18AZ Control lines to oscillating E60, E61, E63, 30 Nm
motor E64, E65, E66
19AZ Return line to valve block E60, E61, E63, 40 Nm

E64, E65, E66
20AZ Holder, valve block, to body E60, E61, E63, 8 Nm
E64, E65, E66
21AZ Connecting nuts, hydraulic E60, E61, E63, 35 Nm
lines (return) E64, E65, E66
22AZ Bracket for jointed rod to front E85, E86 M6 8 Nm

control arm
23AZ Transversal acceleration E60, E61, E63, M6 8 Nm

sensor to body E64, E65, E66
24AZ DYNAMIC DRIVE control unit E60, E61, E63, M8 2.5 Nm

to body E64
E65, E66 M6 4.5 Nm

25AZ Mounted acceleration sensor E65, E66, E67 M6 8 Nm
to bracket
41 14 Reinforcement plate
Tightening Torques
specifications
1AZ Cap nut to reinforcement plate All M5 6 Nm
41 14 Reinforcement plate
Tightening Torques
specifications
1AZ Cap nut to reinforcement plate All M5 6 Nm
41 51 Door
Tightening Torques
1AZ Hinge E46 20 Nm
2AZ Closing bar E46 24 Nm

Adhesive
Body adhesive K1 195 ml 83190413015
Adhesive
Body adhesive K2 2x290 ml 83192355849
Cavity preservation 1000 ml 83422457338
Thin-wall threaded insert M6 41002288195
Thin-wall threaded insert M8 41002361595
Helicoil thread insert M12x30 mm 31 10 6 868 499
Adhesive
Body adhesive K3 2x300 ml 83190417144
Betawipe 4800 10 ml 83192357707
Bonding base VP 206 30 ml 83199407777
Two-component metal filler plus 100+10 g 83192288329
Blind rivet N8 ∅6,5 mm, 83192355998

Clamping area
6.8-8.8 mm
Blind rivet N11 ∅4,8 mm, 83197391057

for CFRP connections Clamping area
2.2-4.7 mm
Blind rivet N12 ∅4,8 mm, 83197391046

for CFRP connections Clamping area
4.5-7.5 mm
4.5-7.5 mm
Plastic nut ∅18 mm 51161943122
Plastic nut ∅22 mm 07147169847
Cavity sealant spray 400 ml 83422457337
Twist drill, high-strength ∅6,8 mm, 83192359262

Length: 79 mm
Twist drill, high-strength ∅4,2 mm, 83192359263

Length: 66 mm
ScotchBrite Multiflex A, very fine 51910402967
Adhesive tape 51717901759
Reinforcement plate, universal 41217275563
Sealant D1 (seam sealing) 310 ml 83422409985
Sealant D2 (seam sealing, spreadable) 310 ml 83422409986
Cavity foamHS1 400 ml 83429410694
Structural foamHS2 420 ml 83190007361
Cavity foam HS3 (2K polyurethane foam) 50 ml 83422288930
Aluminium adhesive tape (adhesive tape) 50 mm 11007769948
Repair rivet for T-bolt ∅2,4 mm, 07148497787

Clamping area
0.8-2.5 mm
Repair rivet for T-bolt ∅2,4 mm, 07148497788

Clamping area
2.5-6.0 mm
PrimerP2 50 ml, 83190302555

Gas cartridge
PrimerP1 50 ml, 83190302556

Bottle
Cavity sealing wax remover 500 ml, 83120390086

Spray bottle
Screw 83190301639
EMC screw, SF Plus, M5x15
Drill bit ∅6,8 mm, 83192460425

Length: 150 mm
Drill bit ∅4,2 mm, 83192460424

Length: 120 mm
Blind rivet N1 83190301414

Ø 6.5 mm ; clamping area 2.8-4.8 mm

Ø 6.5 mm ; clamping area 4.8-6.8 mm
Punch rivet N5 83192158079

Ø 5 mm ; 5 mm long

Ø 6.5 mm ; clamping area 1.5 - 3.5 mm

Dia. 6.5 mm; clamping area 10.8-12.8 mm

Dia. 6.5 mm; clamping area 8.8-10.8 mm
Adhesive

Dia. 4 mm; clamping area 1-3 mm

Dia. 4 mm; clamping area 3-5 mm
Adhesive
Aktivator -205 250 ml, 83190030155

Bottle
Adhesive
Adhesive
Body adhesive K4 50 ml, 83192456697

Cartridge
Punch rivet N4 83192457307

Ø 3 mm ; 4 mm long
51 11 Front Bumper
Tightening Torques
specification
1AZ Bumper to bracket E32 M6 9 Nm
E36 M8 22 Nm
E34 M10 43 Nm
2AZ Bumper and bracket to impact E31 M10 Install bolts with bolt 22 Nm
absorber cement.
E38 / E39 / E46 M10 41 Nm

E36 M10 Install bolts with bolt 55 Nm
cement.
E32 / E34 / E30 M12 48 Nm
/ Mod. 88
E52 38 Nm
3AZ Impact absorber/bracket to E30 / E24 23 Nm
body
E31 / E32 / M6 9 Nm
E34 / E36 /
E38 / E39
E32 / E34 M10 48 Nm
E46 / E52 M8 20 Nm
4AZ Carrier to body E46 / E65 / M8 18 Nm
E66 / E67
E60 / E61 / M8 21 Nm
E63 / E64
5AZ Carrier to deformation element E85 / E86 M10 38 Nm
E85 / E86 M6 8 Nm
E83 M8 28 Nm
6AZ Deformation element to body E85 / E86 M8 19 Nm
E83 M8 25 Nm
7AZ License plate to bumper E46 / E60 / 1 Nm
E61 / E63 /
E64 / E65 / E66
8AZ License plate to bumper (thread E46 / E60 / M5 4.5 Nm
repair) E61 / E63 /
E64 / E65 / E66
9AZ Bumper to front end E60 / E61 5 Nm
51 12 Rear Bumper
Tightening Torques
1AZ Bumper to carrier E31 M10 40 Nm
E32 / E34 / E36 M8 22 Nm

E34 M10 42 Nm
2AZ Bumper / carrier to impact E36 M10 Install bolts with bolt 42 Nm
absorber cement.
E38 M12 45 Nm
E39 M10 45 Nm
E46 M10 41 Nm
E31 / E32 / M12 48 Nm
E34 / E30 /
Mod. 88
E52 M10 38 Nm
E53 M12 55 Nm
E85 / E86 19 Nm
E60 / E61 / M10 36 Nm
E63 / E64
3AZ Impact absorber / carrier to E30 / E24 23 Nm
body
E31 / E32 / E34 M6 9 Nm
E36 / E46 M8 22 Nm
E39 M8 20 Nm
E53 M8 24 Nm
E65 / E66 / E67 38 Nm
E52 / E85 / E86 19 Nm
/ E89 /
E60 / E61 / M10 36 Nm
E63 / E64
E83 M12 71 Nm
4AZ Bumper to side panel E30 7 Nm
5AZ Bracket to side panel E36 / E46 3 Nm
E39 6 Nm
6AZ Holder, bottom, to body E36 8.5 Nm
7AZ Screw for lower panel E36 2.5 Nm
8AZ Bumper to tail panel E60 M6 Replace screw with 2.5 Nm

sealing washer
9AZ Guide to side panel E83 2 Nm
E61 3 Nm
10AZ Guide to rear trim panel E83 2.8 Nm
E61 4.5 Nm
51 13 Trim Parts, Covers, Handle Strip
Tightening Torques
specifications
1AZ Bracket, roof luggage rack on E39 / E46 / M10 20 Nm
body E81 / E82 /
E87 / E90 /
E91 / E92 / E36
/ Z3 and M
Coupé
2AZ Gutter strip to body (plastic E46 1 Nm
nut)
Gutter strip to body (metal nut or E46 1,8 Nm

rivet nut)
3AZ Roof railing to body E39 Centre, front, rear 24 Nm
E61 M8 16 Nm
settling time 15 min
Check 16 Nm
E83 M8 Front
Release nut after settling 15 min
time
Angle of rotation 120 ± 10°
E83 M8 Centre, rear 21 Nm
settling time 15 min
Check 21 Nm
E70 / E84 / E91 19 Nm
E71 / E72 16 Nm
4AZ Handle strip to tailgate E39 / Touring 3 Nm
E46 / E53 2,5 Nm

E83 1,8 Nm
5AZ Cowl panel cover to body E60 / E61 / 2,5 Nm
E63 / E64
6AZ Centre trim to tailgate E65 / E66 / E67 M8 2,5 Nm
7AZ Trim to engine compartment lid E90 / E91 2 Nm
8AZ Additional brake light to tailgate E89 5 Nm
9AZ Threaded bolt on sliding E84 15 Nm

carriage (roof railing)
10AZ Trim strip to gutter strip E88 / E89 / E93 1,8 Nm

51 16 Mirrors, Finishers, Ashtrays, Consoles
Tightening Torques
specifications
1AZ Exterior mirror to front door E31 / E36 / Z3 / 6 Nm
E38 / E39 / E52
E46 / E53 / 6 Nm
E60 / E61 /
E63 / E64 /
E65 / E66 /
E67 / E83 /
E84 / E85 / E86
/ E89
First screw connection 8 Nm
for new mirror
(cutting process of self-
tapping screws)
2AZ Centre console (plastic nut) E30 5 Nm
3AZ Wooden finisher on carrier E38 0.6 Nm
6AZ Front drinks holder to function E38 1.3 Nm

carrier
7AZ Wooden finisher to front drinks E38 0.5 Nm

holder
8AZ Screw-in pin to wooden finisher E46 0.3 Nm

of instrument panel and door
panel
9AZ Housing for exterior mirror to E46 M3 Coupé 1.3 Nm

support
E60 M5 / E63 0.7 Nm
M6
E85 / E86 1.1 Nm
10AZ Brush cable unit to function E65 / E66 / E67 0.5±0.1
carrier Nm
11AZ Roller sunblind to function E65 / E66 / E67 0.5±0.1

carrier Nm
12AZ Roller sunblind to brush cable E65 / E66 / E67 1.2 ± 0.2
unit Nm
13AZ Flap to storage box E85 / E86 0.5 Nm
14AZ Rearview mirror retaining ring E60 M5 / E63 1.1 Nm

on reinforcement plate M6
15AZ Notch adapter to mirror base E60 M5 / E63 3.0 Nm

plate M6
16AZ Centre console to body E89 M6 / Torx 2.4 Nm
17AZ Centre console to body E84 / E89 4.6 Nm

18AZ Glove box housing E84 2.4 Nm
19AZ Bracket, handle, to body E84 6 Nm

51 21 Front Door Locks
Tightening Torques
specification
1AZ Door lock to front door E31 / E36 / E89 Install bolt with bolt 9 Nm
cement.
E46 / E53 / 9.5 Nm
E60 / E61 /
E63 / E64 / 8 Nm
E65 / E66 /
E67 / E85 / E86
E83 10 Nm
2AZ Outside handle to front door E31 / E36 10 Nm
3AZ Door striker to body E24 / E30 24 Nm
E31 / E32 / E34 28 Nm

E65 / E66 / 19 Nm
E67 / E85 / E86
/
E60 / E61 / 21 Nm
E63 / E64 / E89
/
E83 Screw length 18 mm 25 Nm
Screw length 20 mm 18.5 Nm
4AZ Adjustment screw to door lock E46 3 Nm
5AZ Outside handle to lock actuator E53 3.2 Nm
E46 / E63 / 2 Nm
E64 / E83
E60 / E61 3 Nm
6AZ Inside door opener to front E46 / Saloon / 4 Nm
door Touring
E46 / Compact 2.7 Nm

E65 / E66 / 3 Nm
E85 / E86
E67 4 Nm
7AZ Lock actuator/front cover to E60 / E61 / 2.5 Nm
front door E63 / E64
8AZ Lock actuator/rear cover to E60 / E61 / 3.3 Nm

front door E63 / E64
9AZ Door retainer to A-pillar E85 / E86 24 Nm
E60 / E61 21 Nm
E89 27 Nm
10AZ Door retainer to door E60 / E61 / 10 Nm
E85 / E86
E89 12 Nm
11AZ Adapter plate, drive, to door E60 / E61 7.6 Nm
12AZ Drive to adapter plate E60 / E61 4 Nm
13AZ H-strut to inner door plate E89 Replace screw (self- 7 Nm

locking)
14AZ Power window rail to door E89 9.5 Nm
15AZ Carrier, outside door handle, E89 4.4 Nm
to door outer skin
16AZ Adapter, speaker, to inner E89 2 Nm

door plate
17AZ Power window motor to inner E89 Replace screws (self- 7.6 Nm
door plate locking)
51 22 Rear Door Locks
Tightening Torques
1AZ Door lock to rear door E36 Install bolt with bolt 9 Nm
cement.
E46 / E53 / 9 Nm
E60 / E61
E65 / E66 / E67 10 Nm
2AZ Outside handle to rear door E36 10 Nm
3AZ Door striker to body E32 / E34 24 Nm
E60 / E61 / 19 Nm
E65 / E66 / E67
4AZ Adjustment screw to door lock E46 3 Nm
5AZ Outside handle to lock actuator E53 3.2 Nm
E46 / E60 / 2 Nm
E61 / E83
6AZ Inside door opener to rear door E46 / E67 4 Nm
E65 / E66 3 Nm
7AZ Lock actuator/front cover to E60 / E61 2.5 Nm
rear door
8AZ Lock actuator/rear cover to rear E60 / E61 3.3 Nm

door
9AZ Side impact protection to rear E60 / E61 19 Nm

door
10AZ Adapter plate, drive, to door E60 / E61 7.6 Nm
11AZ Drive to adapter plate E60 / E61 4 Nm
12AZ Door retainer to A-pillar E60 / E61 21 Nm
13AZ Door retainer to door E60 / E61 10 Nm

51 23 Hood/bonnet locks
Tightening Torques
specification
1AZ Retaining hook to engine E46 / E52 / 10 Nm
hood/bonnet (replace E53 / E60 /
microencapsulated screws) E61 / E63 /
E64 / E65 /
E66 / E83 /
E85 / E86 /
E89
E38 / E39 12 Nm
E36 Hexagon screw 10 Nm
Torx bolt 12 Nm
2AZ Lock to body (replace E36 / E38 / 10 Nm
microencapsulated screws) E39 / E46 /
E52 / E53 /
E60 / E61 /
E63 / E64 /
E83
E65 / E66 / 8 Nm
E85 / E86
E89 12 Nm
3AZ Lock to engine hood/bonnet E36 / E46 / 10 Nm
(replace microencapsulated E52
screws)
E39 12 Nm
51 32 Front Door Windows
Tightening Torques
specification
1AZ Door window glass holder to E31 / E36 / 9 Nm
roller guide Coupé/Convertible
2AZ Door window glass to holder E31 / E36 / 6 Nm

Coupé/Convertible
E38 / E39 / E46 / 8 Nm
E60 / E61 / E85 /
E86
E63 / E64 / E65 / 10 Nm
E66 / E89 /
3AZ Main stop to window E31 / E36 9 Nm
regulator
4AZ Window guide to body E36 10 Nm
5AZ Window winder E36 6 Nm
6AZ Power window rail to door E89 9.5 Nm

51 33 Power windows, front
Tightening Torques
specifications
1AZ Flat motor to power window E31, E36, E65, 5 Nm
regulator E66
E46, E85, E86 4,5 Nm

E83 3 Nm
E60, E61, E63, 6 Nm
E64
2AZ Window regulator to door E38, E39, E60, 8 Nm
E61, E65, E66,
E83
E36 9 Nm
E46 Replace nut (self-locking) 9,5 Nm
E63, E64 9,5 Nm
3AZ Window regulator to door E85, E86 13,3 Nm
4AZ Window regulator to door E85 / E86 9,5 Nm
5AZ Flat motor to inner door panel E89 7,6 Nm
6AZ Support (terminal clamp) flat E89 9,5 Nm

motor to inner door panel
51 41 Front door trim panel with armrests
Tightening Torques
specification
1AZ Door trim panel to front door E46 / 2.5 Nm
(screw under airbag sticker) Convertible /
Coupé
E85 / E86 / E46 4 Nm
/ Compact
E89 5.0 Nm
E60 / E61 / 8.0 Nm
E65 / E66 /
E67 / E83
2AZ Door trim panel to front door E46 / Saloon / 2.5 Nm
(screw to armrest or door Touring
handle)
E46 / 3.0 Nm
Convertible /
Coupé
E46 / Compact 4 Nm
E63 / E64 3.5 Nm
E65 / E66 / 8.0 Nm
E67 / E83
E85 / E86 7.0 Nm
3AZ Armrest to door trim panel E46 / 2.5 Nm
Convertible /
Coupé
4AZ Door trim panel to front door E46 / Compact 1.1 Nm
E60 / E61 0.8 Nm

E65 / E66 / E67 1.5 Nm
E63 / E64 3.0 Nm
5AZ Wood/decorative strip to door E65 / E66 / E67 1.2 Nm
trim
E60 / E61 0.4 Nm
6AZ Speaker frame to door trim E65 / E66 / E67 0.5 Nm
7AZ Sheet metal nut E65 / E66 / E67 1.0 Nm
8AZ Door handle to door trim panel E85 / E86 0.5 Nm
9AZ Carrier to door trim panel E60 / E61 7.0 Nm

51 42 Rear door trim panel with armrests
Tightening Torques
specification
1AZ Door trim panel to rear door E46 2.7 ± 0.5
Nm
E65 / E66 / E67 8.0 Nm
E60 / E61 0.8 Nm
E83 8.2 Nm
E87 4.2 ± 0.8
Nm
E90 / E91 3.8 ± 0.8
Nm
2AZ Wood/decorative strip to door E65 / E66 / E67 1.2 ± 0.2
trim Nm
E60 / E61 0.4 Nm

3AZ Speaker frame to door trim E65 / E66 / E67 0.5 ±0.2
Nm
4AZ Door trim panel to rear door E60 / E61 8.0 Nm
(screw under airbag sticker)
E83 8.2 Nm
5AZ Carrier to door trim panel E60 / E61 7.0 Nm
6AZ Armrest to door trim panel E87 2.0 ± 0.4

Nm
7AZ Door handle to door trim panel E87 2.0 ± 0.4
Nm
51 43 Side Trim Panel with Armrests
Tightening Torques
1AZ Trim, rear roof pillar (C-pillar) on E38 3.0 Nm
body
E60 3.5 Nm
E61 / E65 / 4.0 Nm
E66 / E67
E83 2.0 Nm
2AZ Trim, front roof pillar (A-pillar) on E46 2.0 Nm
body
E60 / E61 / 2.5 Nm
E63 / E64
E83 2.0 Nm
E65 / E66 / E67 4.5 Nm
3AZ Side trim panel to body E46 / Coupé 3 Nm
E46 / Compact 4.5 Nm

4AZ Armrest to side trim panel E46 / Coupé 2.5 Nm
5AZ Comfort operating unit to E61 3.2 Nm

cross-member
6AZ Drive to comfort operating unit E61 2.8 Nm

51 46 Panel, rear parcel shelf, roller sun blind
Tightening Torques
1AZ Rear parcel shelf to body E65, E66, E67 2.5 Nm
2AZ Roller sun blind to rear parcel E38, E39 3 Nm

shelf
E65, E66, E67 2 Nm
3AZ Roller sun blind with rear parcel E38, E39 6 Nm
shelf to body
E60, E65, E66, 4 Nm
E67, E90, E92
4AZ Cover, rollover bar E88, E93 4.4 Nm
5AZ Trim grille, air outlet, to rollover E88 3 Nm

protection system
E93 8 Nm
6AZ Lashing eye to trim panel, E89 M6 6 Nm
partition
7AZ Trim panel, partition, to body E89 M6 3.5 Nm

51 75 Underbody panelling
Tightening Torques
specifications
1AZ Underbody panelling on body E-series Screw 3 Nm
Nut 2.5 Nm
Oddments tray on body
Plastic nut 3Nm

51 71 Gaskets and loose body components
Tightening Torques
specifications
1AZ Front spoiler to bumper E36 / M3 3 Nm
2AZ Rear spoiler E34 / Touring, M6 6 Nm

E36 / Z3 Coupé
/ M Coupé
E36 / M3 M6 7 Nm
E53 3 Nm
E83 M6 10 Nm
E61 8 Nm
3AZ Reinforcement plate to front E46 / excluding Replace screws
axle support/engine support all-wheel drive
vehicles, E85,
E86
4AZ Trailing link in engine E85, E86 Nut 41 Nm
compartment
Replace screw 56 Nm
Angle of rotation 105 ±15 °
E83 M8 19 Nm
E89 Replace screws 100 Nm
Angle of rotation 105 ± 15 °
5AZ Reinforcement plate/trailing link E46 / M10 Replace screws
to rear axle Convertible,
E85, E86
6AZ Reinforcement plate to body E85, E86 M8 21 Nm
7AZ Trailing link to rear axle E46 / M8 24 Nm

Convertible
E85, E86 Replace nut 24 Nm
8AZ Cross member, A-pillar, to E52 M8 19 Nm
bracket
9AZ Cross member, A-pillar, middle E52 M8 10 Nm
10AZ Strut to transmission tunnel E52 M8 19 Nm
11AZ Cross member, A-pillar, E52 M6 11 Nm

bottom, to bracket
12AZ Support tube to support, E65, E66, E67 M8 21 Nm

steering column upper section
13AZ Support tube to body E85 / E86 M8 20 Nm
14AZ Heating unit to support tube E85, E86 4 Nm
15AZ Support tube to body E60, E61, E63, M8 21 Nm

E64, E83
16AZ Mounting, cover, sill to body E83 M8 5 Nm
17AZ Cover, partition, to body, front E61 2,5 Nm

18AZ Retaining strip, sill trim, to side E61 5 Nm
panel
19AZ Multifunction pan to body E60 / M5 3 Nm
E86 12 Nm
20AZ Underride protection to E60, E61 M8 Replace screws 8 Nm
retaining bracket
21AZ Retaining bracket for E60, E61 M8 Replace screws 8 Nm

underride protection to frame
side member
22AZ Protective mat/protective E60 / Security M6 Screw 10 Nm

cover to body
23AZ Cross connection (engine E89 Screw 7.6 Nm

compartment) to upper
section, support, front panel
24AZ Stiffening plate to body E89 M10 Replace screws
Angle of rotation 105 ±15 °
25AZ Stiffening plate to exhaust E89 Nut 20 Nm
system
26AZ Stiffening plate to body E89 Nut 24 Nm
27AZ Diagonal strut in engine E89 Nut 56 Nm

compartment
Screw 56 Nm
Yellow plastic adhesive tape 83199410979
Adhesive tape, double-sided 54112290978
Cutting cord 81432344272
Cleaning agent R1 100 ml, 83192211217

Bottle
Cleaning agent R2 500 ml 83190417324
Adhesive
Window glass adhesive 300 ml, 83192289286

Rest of World Cartridge
Adhesive

USA Cartridge
Adhesive

CHN Cartridge
52 10 Front seats
Tightening Torques
specification
1AZ Seat to floor plate E31 / E32 / M10 44 Nm
E34 / E36
E36 / Z3 front M8 22 Nm
E36 / Z3 rear M10 43 Nm
E38 / E39 / M10 45 Nm
E46 / E52 /
E53 / E63 /
E64 / E83 / E85
Torque angle 90 °
E60 / E61 / M10 Replace Powerlok screw 44 Nm
E65 / E66 / E67 (trilobular)
2AZ Backrest frame to seat frame E36 60 Nm
E63 / E64 / E83 32 Nm

/ E85
E46 all except Replace screws 32 Nm
Convertible
E65 / E66 / E67 M10 Replace Powerlok screw 33 Nm
/ E60 / E61 (trilobular)
E53 45 Nm
3AZ Support (backrest shell) to E31 6.5 Nm
headrest rail
4AZ Head restraint rail to backrest E31 25 Nm

frame
5AZ Finisher on seat rail E38 / E39 M4 4 Nm
6AZ Seat frame to seat runner E38 / E39 M6 15 Nm
E60 / E61 / E65 M8 27 Nm

/ E66
7AZ Actuating unit to seat frame E46 / E85 10±2 Nm
8AZ Adjusting screw for eccentric E46 / E85 1.4 Nm

element
9AZ Seat pan to seat frame E46 / E53 / 10±2 Nm

E63 / E64 /
E83 / E85
10AZ Microswitch to front seat E46 2±1 Nm
11AZ Backrest frame to seat rail E31 25 Nm
12AZ Trims to seat mechanism E63 / E64 3 Nm
13AZ Trim to seat cushion shell E63 / E64 4.4 Nm
14AZ Backrest frame to seat frame E46 Replace screws 24 +4 Nm

Convertible
- Screw
15AZ Backrest frame to seat frame E46 Replace screws 40 +5 Nm

Convertible
- Pin with knurling and lock nut
16AZ Seat tilt adjuster to seat E46 / E53 / M6 x 10 Replace Taptite screw 9 Nm
mechanism E83 / E85 (trilobular)
17AZ Seat tilt adjuster to seat pan E46 / E53 / 9 Nm
E83 / E85
18AZ Active head restraint E60 / E61 / 8 Nm

E65 / E66 / E67
Sliding rails with gas cartridge
19AZ Belt guide to backrest E85 1.25 Nm
20AZ Kinematic element to E46 3 +2 Nm

backrest frame Convertible
21AZ Gearing for headrest E60 / E61 / 2.5 ±0.5

adjustment E65 / E66 / E67 Nm
52 24 Rear Seat (normal), manual
Tightening Torques
1AZ Backrest on body E38 M6 5 Nm
E60 M8 18.5 Nm
2AZ Head restraint support to E60 M6 Screws, top 5.6 Nm
backrest
Screws, bottom 8 Nm
3AZ Armrest lock to backrest E60 M6 8 Nm
4AZ Backrest lock to backrest E60 M6 19 Nm
5AZ Centre armrest to backrest E60 M6 19 Nm

frame
6AZ Storage compartment casing to E63 / E64 7.5 Nm

body
7AZ Ski bag casing to body E63 / E64 M8 24 Nm

(hexagon screw)
8AZ Lock to body E60 12.5 Nm
9AZ Top Tether eyelet E60 / E63 / 17 Nm

E65 / E66
54 13 Electrical slide/tilt sunroof components
Tightening Torques
specifications
1AZ Drive to cassette E31 / E32 / 2,8 Nm
E34 / E36 /
E38 / E39 /
E46 / E53 / E83
E34 Touring / 3,5 Nm
E60 / E61 /
E63 / E65 /
E66 / E81 /
E82 / E87
E90 / E92 3,8 Nm
E91 2,5 Nm
E70 / E71 / 3Â±0,5
E72 / E84 Nm
54 12 Mechanical components, slide/tilt sunroof
Tightening Torques
specifications
1AZ Cable cover to cassette E36 1,3 Nm
E38 1,6 Nm
2AZ (Glass) cover to gate E34 / Touring 5 Nm
Always use new nuts and
bolts.
E38 / E46 4,5 Nm

All others 6 Nm
All others 6 Nm
3AZ Rail to cassette E31 / E32 / E34 M4 1,8 Nm
E32 / E34 M5 2,8 Nm

4AZ Gearbox to cassette E36 2,8 Nm
5AZ Floating headliner to gate E36 1,5 Nm
E38 / E39 M4 x 6 1,5 Nm

E46 0,9 Nm
6AZ Cassette to body E36 / E34 / M5 3,5 Nm
Touring
E46 M6Â x 14 5,2 Nm
E60 / E65 / M6 5,5 Nm
E66 / E71 / E72
7AZ Mount for wind deflector on E38 / E34 1,2 Nm
cassette
E46 1 Nm
8AZ Stop to floating headliner E38 M4 x 8 0,9 Nm
(glass slide/tilt sunroof)
54 13 Electrical slide/tilt sunroof components
Tightening Torques
specifications
1AZ Drive to cassette E31 / E32 / 2,8 Nm
E34 / E36 /
E38 / E39 /
E46 / E53 / E83
E34 Touring / 3,5 Nm
E60 / E61 /
E63 / E65 /
E66 / E81 /
E82 / E87
E90 / E92 3,8 Nm
E91 2,5 Nm
E70 / E71 / 3Â±0,5
E72 / E84 Nm
54 31 Convertible Top, Frame and Actuation (Mechanical Components)
Tightening Torques
specification
1AZ Storage lock to body E85 / E86 8 Nm
2AZ Hydraulic unit carrier to body E52 11 Nm
3AZ Engine and gear unit E30 10 Nm

Top actuating mechanism to
body/mount
4AZ Engine and gear unit Top E30 / E36 10 Nm

actuating mechanism to body
5AZ Drive arm to engine/gear unit E30 M6 3 Nm
6AZ Drag arm to engine/gear unit E30 M12 12.6 Nm
7AZ Thrust rods to drive arm E30 M4 1.2 Nm
8AZ Thrust rods to convertible top E30 M10 25 Nm
9AZ Guide to convertible top lock E36 / E46 8 Nm
10AZ Headliner to finisher strip E36 1 Nm

(convertible top lock)
11AZ Holder for convertible top E46 21.5 Nm

compartment lid cylinder to
body
12AZ Main bearing to convertible E85 M8 17 Nm

top frame (B-pillar)
13AZ Fold bar to convertible top E52 5 Nm

frame
14AZ Convertible top frame to main E85 M6 11 Nm

bearing
15AZ Convertible top lock to E85 M6 14.5 Nm

convertible top frame (bow 1)
16AZ Window run to convertible top E85 M5 5.1 Nm

frame
17AZ Convertible top catch to E85 M5 8.5 Nm

18AZ Convertible top compartment E64 6 Nm

to body
19AZ Bracket, rear window module, E64 20 Nm

to rear window module
20AZ Bracket, rear window module, E64 20.5 Nm

to roll bar
21AZ Base plate, convertible top, to E64 8.6 Nm

cowl panel
22AZ Main bearing, convertible top E64 Z - direction 20.5 Nm
23AZ Main bearing, convertible top E64 X - direction 8.6 Nm

54 31 Convertible Top, Frame and Actuation (Mechanical Components)
Tightening Torques
specification
1AZ Storage lock to body E85 / E86 8 Nm
2AZ Hydraulic unit carrier to body E52 11 Nm
3AZ Engine and gear unit E30 10 Nm

Top actuating mechanism to
body/mount
4AZ Engine and gear unit Top E30 / E36 10 Nm

actuating mechanism to body
5AZ Drive arm to engine/gear unit E30 M6 3 Nm
6AZ Drag arm to engine/gear unit E30 M12 12.6 Nm
7AZ Thrust rods to drive arm E30 M4 1.2 Nm
8AZ Thrust rods to convertible top E30 M10 25 Nm
9AZ Guide to convertible top lock E36 / E46 8 Nm
10AZ Headliner to finisher strip E36 1 Nm

(convertible top lock)
11AZ Holder for convertible top E46 21.5 Nm

compartment lid cylinder to
body
12AZ Main bearing to convertible E85 M8 17 Nm

top frame (B-pillar)
13AZ Fold bar to convertible top E52 5 Nm

frame
14AZ Convertible top frame to main E85 M6 11 Nm

bearing
15AZ Convertible top lock to E85 M6 14.5 Nm

16AZ Window run to convertible top E85 M5 5.1 Nm

frame
17AZ Convertible top catch to E85 M5 8.5 Nm

18AZ Convertible top compartment E64 6 Nm

to body
19AZ Bracket, rear window module, E64 20 Nm

to rear window module
20AZ Bracket, rear window module, E64 20.5 Nm

to roll bar
21AZ Base plate, convertible top, to E64 8.6 Nm

cowl panel
22AZ Main bearing, convertible top E64 Z - direction 20.5 Nm
23AZ Main bearing, convertible top E64 X - direction 8.6 Nm

Hydraulic fluid for convertible top / lids 250 ml, 54340394395

Bottle
Lubricating grease Renolit RHF 1 20 g, 83192157321

Bag
61 21 Battery with terminal
Tightening Torques
1AZ Battery positive lead, battery E38 / E39 / M6 5 Nm
negative lead, safety battery E46 / E53 /
terminal, IBS E60 / E61 /
E63 / E64 /
(screw connection from above) E65 / E66 /
E67 / E70 /
E71 / E72 /
E81 / E82 /
E83 / E84 /
E85 / E86 /
E87 / E88 /
E90 / E91 /
E92 / E93
E38 / E39 M8 15 Nm
2AZ Power distribution box E60 / E61 / M8 15 Nm
E63 / E64 /
E70 / E71 /
E72 / E81 /
E82 / E87 /
E88 / E90 /
E91 / E92 / E93
E60 / E61 / M6 5 Nm
E63 / E64
3AZ Fuse box E85 / E86 M8 15 Nm
E85 / E86 M6 8 Nm
E85 / E86 M5 5 Nm
4AZ Battery positive lead to E46 / E53 / M8 15 Nm
distributor, safety battery E60 / E61 /
terminal E63 / E64 /
E65 / E66 /
E67 / E70 /
E71 / E72 /
E81 / E82 /
E83 / E85 /
E86 / E87 /
E88 / E90 /
E91 / E92 / E93
61 31 Switch
Tightening Torques
specification
1AZ Temperature switch
99°C All 14 Nm
99°C All 14 Nm
2AZ Oil pressure switch M10, M40, 40 Nm

M42, M21,
Note: Oil and screw in M51, M20,
M30, M50,
M60/1,
M60/2, M70,
S70
S14, S50, S38, 20 Nm
M43
3AZ Reversing light switch All 20 Nm
4AZ Light switch on instrument panel E36, E38 2 Nm
5AZ Transmission switch on shift All 4.5 Nm

block
61 31 Switch
Tightening Torques
specifications
1AZ Ignition starter switch E60 / E61 / 0,4 Nm
E63 / E64
2AZ Reversing light switch E36 / E38 / M12 16,0 Nm
E39 / E46 /
E53 / E60 /
E61 / E63 /
E64 / E81 /
E82 / E83 /
E85 / E86 /
E87 / E88 /
E89 / E90 /
E91 / E92 / E93
3AZ Trim, gear selector switch E70 / E71 / E72 M4 2,0 Nm
4AZ Gear selector switch E70 / E71 / E72 M5 5,0 Nm
5AZ Controller E70 / E71 / E72 M4 1,5 Nm
6AZ Gear selector switch E60 / E61 / M6 7,5 Nm

E63 / E64 /
E89 / E90 M3 /
E92 M3 / E93
M3
7AZ Emergency release to gear E60 / E61 / M4 1,6 Nm
selector switch E63 / E64
8AZ Switch cluster to steering E70 / E71 / 2,5 Nm

column E72 / E81 /
E82 / E84 / E85
/ E87 / E88 /
E89 / E90 /
E91 / E92 / E93
61 61 Windshield Wipers
Tightening Torques
1AZ Wiper motor mounting to wiper E31 LHD / E38 M6 7.5 Nm
console
E31 RL / E36 10 Nm
E39 12 Nm
2AZ Stop for park position to wiper E31 15 Nm
console
3AZ Wiper contact pressure motor E31 / E32 / 6.5 Nm

to wiper console E34 /
E38 to 04/98
4AZ Motor crank to wiper motor E38 M8 21 Nm
E36 / E39 M8 27 Nm
5AZ Wiper shaft nut to body E31 / E36 / 12 Nm
E32 / E34
E46 / E83 10 Nm
6AZ Holder to firewall E31 / E46 / E83 M6 10 Nm
Wiper bracket to firewall E36 CoupÃ© / 10 Nm

E38 / E39
7AZ Upper cowl panel support E31 M4 5 Nm
8AZ Wiper support bracket to E36 10 Nm

firewall
9AZ Wiper support bracket to wiper E36 10 Nm

console
10AZ Wiper arms
Driver's side E31/E39 40 Nm
E38 from 25 Nm
04/98
E46 / E83 30 Nm
Driver's side without ADV (contact E32 / E34 E36 / 25 Nm
pressure adjustment) E38 to
04/98
Driver's side with ADV (contact E32 / E34 21 Nm
pressure adjustment)
E38 to 40 Nm
04/98
Passenger's side E31 / E32 / 25 Nm
E34 / E36 /
E38 / E39
E46 / E83 30 Nm
Scale range
Scale range for left-hand drive vehicles 0 ... -10
Scale range
Scale range for right-hand drive vehicles For right hand drive vehicles, change the preceding
sign of the scale values.
0 ... +10
Protective cover 8319 2 350 087

"Vehicle protection" picture panel
63 13 Turn Signals
Tightening Torques
specification
1AZ Turn signal lights, front E46 compact 1.5 Nm
to headlight
2AZ Turn signal lights, front E46 1.5 Nm

saloon/sedan,
to headlight touring,
coupÃ©,
convertible;
From 09/2001
64 12 Electric auxiliary heater
Tightening Torques
1AZ Battery positive and negative E46 M6 8.8 Nm
leads to auxiliary heater
64 52 Air conditioning compressor
Tightening Torques
specifications
1AZ Refrigerant lines to air- E36/7 M54, M8 20 Nm
conditioning compressor E36/7 S54,
E38, E39, E46,
E52, E53, E60,
E61, E63, E64,
E65, E66, E67,
E83, E85, E87,
E90, E91, E92,
E93
2AZ Filler plug, A/C compressor E36, E38, E39, 30±1 Nm
E46, E52, E53,
E60, E61, E63,
E64, E65, E66,
E67, E83, E85,
E87, E90, E91,
E92, E93
3AZ A/C compressor to carrier M67TU, M54, M8 21 Nm
N62, S85, N54,
N46
N45, N46, M8 19 Nm
M47T2,
M57TU, M57T2
N52K M8 x 87 Replace aluminium
screw!
Angle of rotation 180±15°
N52K M8 x 52 Replace aluminium
screw!
N52 M8 x 87 Replace aluminium
screw/bolt
Replace!
N53 / N51 M8 x 52 Replace aluminium
screw/bolt
Replace!
N53 / N51 M8 x 87 Replace aluminium
screw/bolt
Replace!
E85 S54, E86 20 Nm
S54
4AZ Belt pulley / hub to air M47T2 35±5 Nm
conditioning compressor
5AZ Holder, air conditioning N54 19 Nm

compressor to lower
crankcase section
6AZ Cable clip to air conditioning M47T2 3 Nm

compressor
64 53 Refrigerant Lines and Expansion Valve
Tightening Torques
specifications
1AZ Refrigerant lines to dryer flask E83, E85, E86 M8 20 Nm
2AZ Refrigerant lines to expansion E46, E83, E85, M8 20 Nm

valve/double pipe E86, E81, E82,
E87, E88, E89,
E90, E91, E92,
E93
E53 M8 18 Nm
E84 M8 18.5 NM
3AZ Adapter plate to expansion E85, E86, E89 M6 10 ± 2 Nm
valve
4AZ Expansion valve to heater - A/C E85, E86, E89 M5 5.5 Nm
5AZ Refrigerant line to heater end E85, E86 M6 8.6 Nm

panel
6AZ Refrigerant lines to capacitor E60, E61, E63, M8 20 Nm

E64, E81, E82,
E83, E85, E86,
E87, E88, E89,
E90, E91, E92,
E93
E84 M8 18.5 Nm
7AZ Refrigerant lines to expansion E60, E61, E63, M6 8.8 Nm
valve E64
8AZ Refrigerant line to assembly E60, E61, E63, M6 7.6 Nm

compartment partition E64
reinforcement
9AZ Expansion valve to heater - A/C E46, E60, E61, M5 5.5 Nm

E63, E64, E83
10AZ Refrigerant line to body E46, E83 M6 5.5 Nm
11AZ Double pipe to expansion E46, E83 M6 8.0 Nm

valve
12AZ Screw plug to capacitor E53, E81, E82 / 3.0 ± 0.5

E84, E87, E88, Nm
E90, E91, E92
13AZ Expansion valve to retaining E81, E82, E84, M6 5.5 Nm
clip E87, E88, E90,
E91, E92, E93
14AZ Pressure sensor in refrigerant E53, E60, E61, 10 Nm
line E63, E64, E65,
E66, E81, E82,
E83, E84, E85,
E86, E87, E88,
E89, E90, E91,
E92, E93
15AZ Refrigerant line to adapter E60 / N53, E61 18 Nm
lead / N53, E63 /
N53, E64 /
N53, E60 /
N54, E61 / N54
64 53 Condenser and Drier with Pipes
Tightening Torques
1AZ Pipe connections E46 5/8” 20 Nm
E46 3/4” 39 Nm
E46 7/8” 42 Nm
E46 11/16” 48 Nm
64 53 Refrigerant Lines and Expansion Valve
Tightening Torques
specifications
1AZ Refrigerant lines to dryer flask E83, E85, E86 M8 20 Nm
2AZ Refrigerant lines to expansion E46, E83, E85, M8 20 Nm

valve/double pipe E86, E81, E82,
E87, E88, E89,
E90, E91, E92,
E93
E53 M8 18 Nm
E84 M8 18.5 NM
3AZ Adapter plate to expansion E85, E86, E89 M6 10 ± 2 Nm
valve
4AZ Expansion valve to heater - A/C E85, E86, E89 M5 5.5 Nm
5AZ Refrigerant line to heater end E85, E86 M6 8.6 Nm

panel
6AZ Refrigerant lines to capacitor E60, E61, E63, M8 20 Nm

E64, E81, E82,
E83, E85, E86,
E87, E88, E89,
E90, E91, E92,
E93
E84 M8 18.5 Nm
7AZ Refrigerant lines to expansion E60, E61, E63, M6 8.8 Nm
valve E64
8AZ Refrigerant line to assembly E60, E61, E63, M6 7.6 Nm

compartment partition E64
reinforcement
9AZ Expansion valve to heater - A/C E46, E60, E61, M5 5.5 Nm

E63, E64, E83
10AZ Refrigerant line to body E46, E83 M6 5.5 Nm
11AZ Double pipe to expansion E46, E83 M6 8.0 Nm

valve
12AZ Screw plug to capacitor E53, E81, E82 / 3.0 ± 0.5

E84, E87, E88, Nm
E90, E91, E92
13AZ Expansion valve to retaining E81, E82, E84, M6 5.5 Nm
clip E87, E88, E90,
E91, E92, E93
14AZ Pressure sensor in refrigerant E53, E60, E61, 10 Nm
line E63, E64, E65,
E66, E81, E82,
E83, E84, E85,
E86, E87, E88,
E89, E90, E91,
E92, E93
15AZ Refrigerant line to adapter E60 / N53, E61 18 Nm
lead / N53, E63 /
N53, E64 /
N53, E60 /
N54, E61 / N54
Refrigerant 12 kg, 83199408386

R134a Bottle
Heating and air conditioning system cleaning agent 1000 ml, 83192180507
Bottle
5000 ml, 83192219932
Bottle
Heating and air conditioning system cleaning agent 100 ml, 83192409611
Can
Ozonizer 100 ml, 83192318666

Can
Refrigerant oil PAG-Ã–L Denso ND8 500 ml, 81342147762

Can
UV additive Waeco 500 ml, 83192232504

Can
Cartridge set for leak detector case 3x , 83192232569

Cartridge
Cleaning agent UV filter 237 ml, 83192243942

Spray bottle
Refrigerant 5 kg, 83192354790

R1234yf Bottle
UV additive 472,5 ml, 83192243934

Can
Refrigerant oil Sanden SP-A2 250 ml, 83222339920

For invoicing purposes only. EU 10 ml, 83192287382
10 ml, 83192287382
TU*
Refrigerant oil 250 ml, 81229407724

10 ml, 83190143174
TU*
65 77 Airbag triggering control
Tightening Torques
specifications
1AZ Airbag control unit E36, E38, E39, 8,8 Nm
E46, E52, E53
E85 4,6 Nm
E60, E61, E63, 8,0 Nm
E64, E81, E83,
E87, E90, E91,
E92, E93
E60 / from 8,0 Nm
09/2005, E61 /
from 09/2005
2AZ Impact sensor for side airbag E36, E38, E39, 5,5 Nm
E46, E52, E53
3AZ Sensor, front E83, E85, E86 Replace screws 8,0 Nm
4AZ Sensor, A-pillar E65, E66 4,5 Nm
5AZ Sensor, B-pillar E60, E61, E63, 4,6 Nm

E64, E65, E66,
E85, E86
E81, E83, E87, 8,0 Nm
E90, E91, E92,
E93
6AZ Sensor, vehicle centre E65, E66 5,5 Nm
E60, E61, E63, 8,0 Nm

E64
7AZ Sensor, front door E65, E66 8,2 Nm
E60,, E61, E90, 8,0 Nm

E91, E92, E93
E85, E86 5,6 Nm
E83 4,6 Nm
8AZ Sensor, rear seat E65, E66 8,0 Nm
9AZ Acceleration sensor, front E63, E64, E90, Replace screws 8,0 Nm
E91, E92, E93
E60, E61 Replace screws 7,0 Nm
67 62 Drives, power windows
Tightening Torques
1AZ Motor to window regulator E46 / E85 / 4.5 Nm
E86 / E93
E31 / E36 / E65 5 Nm
/ E66
E81 / E82 / 3 Nm
E83 / E88
E60 / E61 / 6 Nm
E63 / E64 /
E84 / E87 /
E90 / E91 /
E92 / E93
E70 / E71 / E72 Observe screwing 6 Nm
sequence
E89 Replace bolts. 7.6 Nm
71 60 Trailer Hitch
Tightening Torques
1AZ E36, except Nut M10 and 1. M10 screws to trailer 59 Nm
compact and screw M10 tow hitch
Z3 10.9 2. M10 screws to axial
struts
3. M10 collar nuts to
reinforcement brackets
2AZ E32 M40 Slotted nut for take-up 220 Nm
pipe to coupling with
thread locking compound
Loctite 638
3AZ E31 M10 8.8 1. M10 screws 42 Nm
screw
E31 M8 nut 2. M8 nuts 22 Nm
4AZ E36 compact Nut M10 and 1. Collar nuts M10 trailer 59 Nm
and Z3 screw M10 tow hitch / rear panel
10.9 2. M10 screws to trailer
tow hitch / rear panel
3. M10 screws to axial
struts
5AZ E39 Nut M10 and 1. Collar nuts M10 trailer 59 Nm
screw M10 tow hitch / rear panel
10.9 2. M10 screws to axial
struts
6AZ E38 Nut M10 and 1. M10 screws, bottom, 59 Nm
screw M10 to cross-member
10.9 2. M10 screws, top, to
luggage compartment
floor
3. M10 screws, front, to
axial struts
4. M10 screws, rear, to
axial struts
struts
struts, top and bottom
71 60 Trailer tow hitch
Tightening Torques
specifications
1AZ Trailer tow hitch on body E46 Nut M10 and First collar nut M10on 59 Nm
screw M10 trailer tow hitch / rear
10.9 panel
Second screw M10 to
longitudinal strut
E84 / E90 / M12 Replace screw/nut 108 Nm
E91 / E92 / E93
2AZ Release unit to trailer tow hitch E90 / E91 / M6Â x 35 Replace 5 Nm
E92 / E93 microencapsulated screw!
72 11 Seat Belts
Tightening Torques
specification
1AZ Seat belt, E36 / E31 / Replace screws 31 Nm
E38 / E39 /
Automatic reel, E46 / E52 /
Lower strap, E53 / E83
Anchor fitting,
Belt tensioner to body
Seat belt on B-pillar All, except E53 Replace screws 31 Nm
Seat belt / belt tensioner to seat, All, except E52 / Replace screws 48 Nm
on Touring also to rear seat E53
backrest
2AZ Screws for seatbelt height All Replace screws 22 Nm

adjustment on body
3AZ Seat belt to seat E31 Replace screws 47 Nm

Install bolt with bolt cement.
4AZ Seat belt to backrest E31 Replace screws 24 Nm
5AZ Headrest to backrest E31 24 Nm
6AZ Seat belt at belt height All Replace screws 31 Nm

adjustment (reversing clip)
7AZ Tension relief between roller E39/2 24 Nm

sun blind bracket and backrest
lock bracket
8AZ Retaining angle, belt tensioner E46 / E83 Replace screws 24 Nm

to seat rail
9AZ Slide bar to body E46 Replace screws 44 Nm
10AZ Counter-support plate to E53 39 Nm

body, B- and C-pillars
11AZ Seat belt to seat (end fitting) All Replace screws 45 Nm
12AZ Screw of seatbelt height E53 Replace screws 31 Nm

adjuster to counter-support
plate
13AZ Belt tensioner to seat E83 Replace screws 45 Nm
E52 / E53 Replace screws 31 Nm

14AZ Inertial reel unit to body / B- E53 / E83 Replace screws 31 Nm
pillar
15AZ Automatic reel on rear seat E53 Replace screws 45 Nm

backrest
E83 Replace screws 35 Nm
16AZ Belt guide to front seat (sash E46 Replace screws 8 Nm
guide to head restraint clip) Convertible
17AZ Automatic reel to front seat E46 Replace screws 39 Nm
backrest Convertible
18AZ Coupling gearing to centering E46 2.5 Nm

pin Convertible
19AZ Corner hoop to side panel, E53 / E83 3 Â±0.5 Nm

inner (B-pillar)
20AZ Upper belt loop to body E83 Replace screws 31 Nm
21AZ Automatic reel to body E83 Replace screws 31 Nm

72 12 Airbag modules
Tightening Torques
specification
1AZ Airbag module in door, door trim E36 / E38 / 8.5 Nm
panel or in side frame, holder E39 / E46 /
E52 / E53
2AZ Gas generator of ITS head E38 / E53 M6 nut 4 Nm
airbag on body
E83 6.5 Nm
3AZ Bracket of ITS head airbag on E38 / E39 / E46 Metal screw 2.5 Nm
body
E83 6.5 Nm
4AZ ITS head airbag to body (end E38 / E39 / 11 Nm
fitting) E46 / E53
E83 6.5 Nm
5AZ Additional steel bracket for ITS E38 / L7 Self-tapping 3 Nm
head airbag on body screw M5
6AZ Gas generator of ITS head E39 / E46 M6 nut or 4 Nm

airbag on body oval-head
screw,
thread-
tapping
7AZ Passenger airbag module on E36 except Z3 / M8 22 Nm
instrument panel carrier E52
8AZ Passenger airbag module on E36 Z3 M8 24 Nm

instrument panel carrier
9AZ Passenger airbag module on E38 / E39 M6 nut 10 Nm

E83 M6 nut with 6 Nm
pressed-on
washer
E85 M6 8 Nm
10AZ Retaining strap for cover, E46 / E52 / E83 M6 9 Nm
passenger airbag module on
11AZ Passenger airbag module on E46 / E53 M8 nut 22 Nm

12AZ Head airbag cassette in rear E38 / E39 M6 11 Nm

compartment to body
13AZ Gas generator, head airbag in E38 M6 nut 4 Nm

rear compartment, to body
14AZ Bracket of ITS head airbag on E46 CoupÃ© / Metal screw 4 Nm

body E53
15AZ ITS head airbag gas generator E38 M6 4 Nm

to body for conversion from
1.0 to 1.1
16AZ Gas generator, head airbag, in E39 M6 4 Nm
rear comp. to body (parcel
shelf)
17AZ Head airbag cassette in rear E53 Metal screw 3 Nm

compartment to body
18AZ Gas generator, head airbag in E53 M6 4 Nm

rear compartment, to body
19AZ Airbag module for knee E85 M6 Replace screws 8 Nm

protection
Assembly aids
Lubricants G14 900 ml, 83232360412

Can
Adhesive
Adhesive set K6 25 ml, 83192317925

Tube
Multifunction spray Brunox 400 ml, 83230418567

Spray can
Paints and colours
Emergency program base filler 2K spray 200 ml, 51910432615

Application time 8 h
Paints and colours
INOX spray welding primer 500 ml 83400409992
Paints and colours
Spray paint, black matt 400 ml 51911900346
Paints and colours
Paint spray aerosol, inside filler of spare wheel well 400 ml 51910411026
00 01 03 (035)
Abbreviations
All models
Introduction
There are a large number of abbreviations used at BMW: in development, production, organisation,
sales/marketing, test plans and technical vehicle documentation.
BMW language: about 1,500 abbreviations used in technical areas alone!

To assist with diagnoses, BMW Service Technology has several lists of abbreviations. These abbreviations
should not appear cryptic, particularly to those who are coming into the workshop for the first time or from other
departments, but also anyone else interested in technology. Abbreviations can be simple keywords, whose
meaning is clear. These lists of abbreviations may help to clarify.
Lists of abbreviations
The following lists of abbreviations are available:
Series and models with images: Update 01/2013
Series from recent years with images, sales names, engines etc. [more ...]
Engines since 1983: Update 01/2013
Engines and the related electronic engine control [more ...]
Gearbox: Update 01/2013
Gearboxes and the related electronic transmission control [more ...]
Control units: Update 01/2013
Current control units in diagnosis and programming [more ...]
BMW Service Technology - Glossary: Update 07/2007
More than 700 abbreviations used in BMW Service Technology. New in relation to the 2004 list of
abbreviations:
Some new abbreviations have been included.
Some abbreviations have been deleted. Reason: Die number of abbreviations should be kept as
low as possible, in order to optimise and simplify the reading process.
Some of the text the ”Use” column has been revised.
For technical reasons, the glossary is divided into the following systems:
Introduction, abbreviations with numerals and characters [more ...]
-A-
-B-
-C-
-D-
-E-
-F-
-G-
-H-
-I-
-J-
-K-
-L-
-M-
-N-
-O-
-P-
-Q-
-R-
-S-
-T-
-U-
-V -
-W -
-X-
-Z-
Overview of Unified Parts Group [more ...]
Note: Thanks for your support and feedback.
Our sincere thanks to our colleagues in the diagnosis, programming, and integration departments,
to our repair instruction authors and Aftersales Training staff for taking the trouble to draw up their
lists, and for their support in aligning the data. Our special thanks to the company archives for
providing images of earlier models, and for their extensive and detailed editing work.
We can assume no liability for printing errors or inaccuracies in this document and reserve the right to
introduce technical modifications at any time.
11 02 05 (130)
Vacuum supply
All models
Introduction
Vacuum is principally used for the brake booster.
The vacuum in the inlet pipe depends on the varying engine load.
Diesel engines do not normally have any vacuum in the inlet pipe. Vacuum on diesel engines is provided by a
pump that generates the required vacuum.
On spark-ignition engines with Valvetronic, the throttle valve is almost always open when driving. This means
that there is a lower low air pressure in the intake manifold.
Spark-ignition engines with low vacuum in the inlet pipe also have a pump that generates additional vacuum.
[System overview ...]
Brief description of components
The following components are involved in the vacuum supply system:
Mechanical vacuum pump
A mechanic vacuum pump is fitted to diesel engines and spark-ignition engines with Valvetronic.
The vacuum pump is mechanically driven by the engine, e.g. via the exhaust camshaft.
Suction-jet pump
As a rule, the suction-jet pump boosts the vacuum in the inlet pipe.
[more ...]
Electric vacuum pump
On some engines, an electric vacuum pump is fitted for additional vacuum supply.
In certain temporary operating situations, the vacuum in the inlet pipe may be too low. In such cases, the
inlet pipe vacuum cannot be adequately boosted by the suction-jet pump. In these situations, the electric
vacuum pump ensures that sufficient vacuum is available.
Reason: After a cold start, an operating situation occurs in which there is very little inlet pipe vacuum due
to the higher load. The electric vacuum pump is actuated for a certain time. This ensures that the brake is
sufficiently boosted when manoeuvring.
After a cold start, the DME will actuate the electric vacuum pump once only for max. 60 seconds.
The electric vacuum pump is actuated in the following situations:
Engine-running signal from DME
Coolant temperature below 60 °C
The electric vacuum pump is a vane-cell pump.
Throttle valve
The throttle valve changes the cross-sectional area of the inlet pipe. This creates an inlet pipe vacuum
behind the throttle valve, especially in overrun mode.
DME or DDE: Digital engine electronics or digital diesel electronics
The DME or DDE actuates the components needed for system functions (e.g. solenoid valves, electric
switching valves, electropneumatic pressure converters).
System functions
The system functions of the vacuum system are described using the following examples:
Power assist for brakes
Actuation of exhaust flaps
Adjustment of variable turbine geometry
Actuation of controlled damping mounts
Exhaust gas recirculation
Drawing off of blow-by gases from crankcase
Blowing out activated charcoal filter
Power assist for brakes

The brake booster amplifies the force excerpted at the brake pedal. To do this, the brake booster stores
part of the vacuum generated by the engine. The vacuum then amplifies the force generated by pressure
on the brake pedal.
Actuation of exhaust flap

A controlled electropneumatic exhaust flap is fitted in the exhaust system. The exhaust flap enhances
active sound-damping. The exhaust flap is closed by vacuum.
Adjustment of variable turbine geometry

The variable turbine geometry controls the boost pressure via adjustable guide vanes. The guide vanes
are actuated by vacuum.
Actuation of controlled damping mounts

In the basic setting, there is no vacuum at the control component od the mount. The bypass in the mount is
closed. Hydraulic fluid flows back and forth through a ring channel between the upper and lower chambers in
the mount. The mount acts like a conventional hydraulic bearing. The mount has hard damping.
If a vacuum is applied to the mount's control component, the bypass will open. The hydraulic fluid then flows
back and forth between the chambers through a larger cross-sectional area. The mount has softer damping.
Exhaust gas recirculation

With exhaust gas recirculation, part of the exhaust gas is take from behind the exhaust manifold. This is
then fed back into the engine through the intake air duct. The exhaust gas recirculation pipe is located at the
inlet to the intake manifold.
If a vacuum is applied to the exhaust gas recirculation valve, the exhaust gas recirculation pipe will open.
The level of vacuum is determined by the opening in the exhaust gas recirculation valve.
Exhaust gases flow through a connecting pipe to the exhaust manifold and into the intake manifold.
Drawing off of blow-by gases from crankcase
The crankcase ventilation system uses vacuum to bleed the blow-by gases out of the engine block.
Blow-by gases are the small portion of the cyinder fill that passes by the piston rings and into the crankcase
during compression. If the blow-by gases are not bled from the engine block through the crankcase
ventilation system, they will accumulate in the crankcase. The blow-by gases would then apply pressure on
the pistons from below. This would have a negative effect on the downward movement of the pistons in the
intake stroke and operating stroke.
Blowing out activated charcoal filter

The fuel tank vent hose is connected to an activated charcoal filter. Vapours from the fuel tank are collected
in the activated charcoal filter. The activated charcoal filter is connected to the intake manifold by a pipe. A
fuel evaporation control valve is fitted in this pipe. When the fuel evaporation control valve is opened, the
vacuum in the manifold draws in fresh air. At the same time, the fresh air blows out the fuel vapours
collected in the activated charcoal filter.
Notes for service staff

Service staff should note the following points:
General information: ---
Diagnosis: ---
Encoding/programming: ---
Car and Key Memory: ---
Subject to change.
16 02 03 (036)
Electronically controlled fuel pump
E46, E60, E61, E63, E64, E87, E90, E91
Introduction
The electric fuel pump in the “Fuel pump electronic control” system is activated as and when required. The DME
or DDE control unit calculates the amount of fuel required at the given point in time. The EKP control unit
controls the electric fuel pump on the basis of mappings so that the electric fuel pump delivers the exact
amount of fuel required.
In conventional systems, the electric fuel pump is operated continuously at maximum speed using the highest
on-board supply voltage available. The maximum amount of fuel that may be required is made available
regardless of the operating conditions.
The electronically controlled fuel pump system optimises the supply of fuel and reduces fuel consumption.
The electronically controlled fuel pump system is available for both petrol and diesel engines.
Note: In this case, EKP = “Electronic fuel pump control” .
The abbreviation EKP is often used to refer to the electric fuel pump itself. The electronically
controlled fuel pump system described here is controlled by a control unit called the EKP control
unit. The abbreviation EKP is used here to refer to the system as a whole.
The electronically controlled fuel pump system comprises the following components:
On E46 vehicles:
DME control unit
The DME control unit (digital engine electronics) calculates the amount of fuel required based on the
driver's request and the operating status of the engine.
Local CAN
The EKP control unit communicates with the DME control unit via the local CAN.
K-bus (body bus)
Diagnosis is performed through the K-bus. In the event of a crash, the EKP control unit is deactivated by
the K-bus.
In the E60, E61, E63, E64, E87, E90, E91:
DDE control unit
The DDE control unit (digital diesel electronics) calculates the amount of fuel required based on the
driver's request and the operating status of the engine.
PT-CAN
The EKP control unit communicates with the DDE control unit via the PT-CAN (Powertrain CAN).
The E46, E60, E61, E63, E64, E87, E90 and E91 have the following in common:
EKP control unit
The EKP control unit controls the speed of the electric fuel pump in accordance with the DME or DDE fuel
volume calculation. [more ...]
Regulated fuel pump
The controlled fuel pump is a system comprising an electric fuel pump and control unit in which the fuel
pump not only pumps, it also pumps more or less depending on the requirements.
The following types of fuel pump are installed:

E46: side channel pump (2-speed fuel pump)
E60, E61, E63, E64: roller-cell pump
E87, E90, E91: G-rotor pump
System function
The electronically controlled fuel pump system comprises the following functions:
Delivery of fuel according to requirements
Cooling and lubrication of high-pressure pump (diesel engine)
Emergency operation
Delivery of fuel according to requirements
Amount of fuel required by the engine is calculated by the DME or DDE control unit. The total volume
required is transmitted as a message to the EKP control unit via the local CAN or PT-CAN. The EKP
control unit converts this message into an output voltage. This output voltage is then used to control the
speed of the electric fuel pump. This achieves a delivery which corresponds with the requirements.
Cooling and lubrication of high-pressure pump (diesel engine)

On diesel engines, the fuel is also used to cool and lubricate the high-pressure pump.
The lower limit of the amount of fuel to be delivered is not determined by the minimum amount of fuel
required by the engine. The parameters for lubrication and cooling of the high-pressure pump are also
decisive factors.
Emergency operation
In the event that communication with the DME or DDE fails or is faulty, the EKP control unit will switch to
emergency operation. The electric fuel pump is fully activated.
General information: [more ...]
Diagnosis: ---
Encoding/programming: [more ...]
Car & Key Memory: ---
Subject to change.
16 01 00 (557)
Functional description for fuel supply system
E38, E39, E46, E52, E53
General
Fuel supply systems in petrol engines
Fuel system
The fuel pump in the fuel tank generates pressure in the fuel system, which is set by the pressure regulator
valve to a certain level.
Tank safety valve

The tank safety valve is a closed system that is bled via a carbon canister. The carbon in the carbon
canister is stored as granules. The large surface of the granules traps the fuel vapour, that occurs in the fuel
tank. The carbon canister needs to be refreshed regularly in order to be able to continue to store fuel
vapour. This is done by flushing it with fresh air from the intake pipe. This process is controlled by the engine
control unit.
Diesel engine fuel supply system
Fuel system
The fuel pump in the fuel tank supplies the engine with fuel. Two types of high pressure pump are used for
direct injection.
1. The power distribution box injection pump. This supplies each cylinder directly with fuel via individual
injector nozzles.
2. The high pressure pump for the common rail systems. This generates the required pressure in the
fuel injection pipe for all injector nozzles.
With common rail systems another pump (inline pump, M57/geared pump, M67) is connected between the
high pressure pump and the fuel pump. This pump aids the fuel pump in the fuel tank during times of high fuel
requirement.
Tank safety valve

Diesel fuel is slow-evaporating, therefore no carbon canister is required. The fuel tank is ventilation directly
into the atmosphere.
1. Fuel supply system E38/39
1.1 Part designation
1. Fuel tank (E38 steel, E39 plastic) 16. Float valve (USA only)
2. Fuel pump 17. Fuel return line
3. Surge tank 18. Fuel delivery line
4. Suction jet pump 19. Fuel filter
5. Pressure limit valve 20. Pressure regulator
6. Run-out protection valve 21. 3/2-way valve (M52 US only)
7. Pressure test line (USA only) 22. Fuel injection pipe
7. Refuelling tank ventilation line (worldwide) 23. Purge air line
8. Non-return valve 24. Engine control unit
9. Fuel filler pipe 25. Tank vent valve
10. Fuel filler cap 26. Intake pipe
11. Fuel tank expansion line 27. Vacuum line (leak diagnosis pump USA only)
12. Refuelling tank ventilation line (USA only) 28. Carbon canister
12. Service tank ventilation line (worldwide) 29. Evaporation line
13. Service tank ventilation line 30. Leakage diagnosis pump (USA only)
14. Expansion tank 31. Tank leakage diagnosis module (USA only)
15. Roll-over valve 32. Dust filter (USA only)
1.2 Functional description (see also graphics 1.4/1.5/1.6/1.7/1.8)

Fuel system
The saddle-shaped fuel tank contains the surge tank with an electric fuel pump on its right side. The surge tank
ensures that the fuel pump is properly supplied in all vehicle operating conditions. The suction jet pump built
into the floor of the surge tank supplies the surge tank with fuel. The fuel is pumped from the left side of the fuel
tank into the surge tank via the suction jet pump integrated in the tank expansion line. Both suction jet pumps
are operated by the fuel return line.
The pressure limit valve controls the required pressure to operate the suction jet pump. The run-out
protection valve secures the fuel return line. If the pressure falls if the fuel return line is damaged or
disconnected, the valve closes. This prevents the fuel from running out of the fuel tank in extreme vehicle
positions (rollover, on an incline etc.). The non-return valve prevents the fuel from sloshing back into the filler
pipe after the fuel pump nozzle is shut.
Fuel supply to the engine
M52TU (see graphic 1.5, view A)
The fuel is routed from the electric fuel pump via the fuel delivery line and the fuel filter to the fuel injection pipe.
The fuel flows back into the fuel tank via the pressure regulator on fuel injection pipe and the fuel return line.
M52 USA and M73 (see graphics 1.5/1.6)
The fuel is routed from the electric fuel pump via the fuel delivery line and the fuel filter to the fuel injection pipe.
The reverse flow into the fuel tank takes place via the 3/2-way valve (see view A), the pressure regulator and
the fuel return line. This engine fuel circuit with reverse flow from the fuel injection pipe is used for engine start
and for a set time less than 1 minute after this. After this phase the 3/2-way valve triggers and stops the fuel
reverse flow from the fuel injection pipe. At the same time the branch line directly on the fuel filter is activated
by the 3/2-way valve on the pressure regulator (see view B). The fuel injection pipe is now free from return
fuel.
M62TU/54 (see graphic 1.4, view B and graphics 1.7/1.8)
The pressure regulator and fuel filter are incorporated in a single unit. The fuel is routed from the electric fuel
pump via the fuel delivery line and the fuel filter/pressure regulator to the fuel injection pipe. The fuel injection
pipe is return-free. The fuel flows directly from the fuel filter/pressure regulator back into the fuel tank.
Tank safety valve USA (see graphics 1.6/1.7/1.8)
The fuel tank is vented during refuelling via the refuelling vent line.
Because of its large cross-section, the refuelling ventilation line directs the displaced volume (fuel vapours) at
high speed through the expansion tank to the carbon canister. The activated carbon retains the fuel contained
in the fuel vapours. The cleaned air is discharged to the atmosphere via the evaporation line, the leak
diagnosis pump/tank leak diagnosis module and the dust filter. Ventilation during vehicle operation is done in
the same way via the refuelling tank ventilation line and the service tank ventilation line. The condensed
components of the fuel vapour go from the expansion tank via the service tank ventilation line back into the
fuel tank. The float valve in the refuelling tank ventilation line (E39 only) is closed by the rising fuel if the tank is
overfilled. This prevents the expansion tank from being overfilled. The roll-over valve on the top side of the
expansion tank closes if the vehicle rolls over. This prevents fuel from spilling into the carbon canister. The
carbon canister is regenerated by purging with fresh air. The engine control unit opens the tank vent valve.
This means there is an intake pipe vacuum at the purge air line. This flushes the carbon canister with fresh air
via the evaporation line, the leakage diagnosis pump/the tank leakage diagnosis module and the dust filter.
The fuel constituents bound by the activated carbon are flushed out by the supplied air and directed via the
purge air line to the engine for combustion. This operation is only possible while the engine is running.
Tank safety valve worldwide (see graphics 1.4/1.5)
See tank safety valve USA with the following exceptions:
1. The fuel tank ventilation during refuelling takes place via the refuelling vent line which directs the
displaced volume into the fuel filler neck. Instead of the large cross-section refuelling tank ventilation line
(USA), there is a second service tank ventilation line with a small cross-section. There is no float valve.
3. There is no leakage diagnosis pump or tank leakage diagnosis module and dust filter
Leakage diagnosis for the tank ventilation system USA (see graphics 1.6/1.7/1.8)
The leakage diagnosis pump (see graphics 1.6/1.7) / tank leakage diagnosis module (see graphic 1.8) are
used for leak diagnosis for the tank ventilation system within the on-board diagnosis laid down by legislation.
The tank ventilation system is pressurised and the pressure loss is detected in the event of a leak.In the case
of the leakage diagnosis pump, the pressure loss is measured over the post-pumping time. The pump is
operated with a vacuum from the intake pipe via the vacuum line.The diagnostic module for tank leaks is
activated by the DME control unit and detects the pressure loss by way of the power consumption of the
integrated pump. The air required for this purpose is supplied via the dust filter. Both systems are actuated by
the engine control unit.The pressure test line establishes the connection between fuel tank and fuel filler neck.
This enables a leak to be detected in the fuel filler pipe-fuel tank cap area.
Determining fill level in fuel tank:
The fuel level is measured by means of lever sensors on both sides of the fuel tank. The right-hand lever
sensor is integrated into the fuel delivery unit. The left-hand lever sensor is located in the left sensor unit. The
combination of the determined ohm values from the right and left lever sensor produces the actual fluid level in
the fuel tank.
1.3. Operating data, fuel system
Pressure regulator: 3.5 barS62 5 bar)
Operating pressure of the suction jet pumps: 1 - 1.3 bar
1.4. Fuel supply system E38/39 M52TU/M54/M62TU
1.5. Fuel supply system E38 M73

1.6 Fuel supply system E38/39 M52/73 USA
1.7 Fuel supply system E38/39, M62 USA (LDP)
1.8 Fuel supply system E39, M54/62 USA (TLDM)
2. Fuel supply system E46
1. Fuel tank (plastic) 18. Roll-over valve

2. Fuel pump 19. Float valve (USA only)
3. Surge tank 20. Fuel filter
4. Pressure limit valve 21. Pressure regulator
5. Run-out protection valve 22. 3/2-way valve (M52 US only, M73)
6. Suction jet pump 23. Fuel injection pipe
7. Fuel tank expansion line 24. Engine control unit
8. Non-return valve 25. Intake pipe
9. Fuel filler pipe 26. Tank vent valve
10. Fuel filler cap 27. Purge air line
11. Pressure test line (USA only) 28. Tank ventilation line
11. Refuelling tank ventilation line (worldwide) 29. Vacuum line (leak diagnosis pump USA only)
12. Fuel delivery line 30. Evaporation line
14. Service tank ventilation line 32. Carbon canister (USA only)
15. Refuelling tank ventilation line (USA only) 33. Leakage diagnosis pump (USA only)
15. Additional tank ventilation line (Japan) 34. Dust filter (USA only)
16. Service tank ventilation line 35. Tank leakage diagnosis module (USA only)
17. Expansion tank
2.2 Functional description (see also graphics 2.4/2.5/2.6/2.7)

Fuel system
The saddle-shaped fuel tank contains the surge tank with an electric fuel pump on its right side. The surge tank
ensures that the fuel pump is properly supplied in all vehicle operating conditions. The fuel is pumped from the
right side of the fuel tank into the surge tank via the suction jet pump integrated in the tank expansion line. The
suction jet pump is operated via the fuel return line.
The pressure limit valve controls the required pressure to operate the suction jet pump. The run-out
protection valve secures the fuel return line. If the pressure falls if the fuel return line is damaged or
disconnected, the valve closes. This prevents the fuel from running out of the fuel tank in extreme vehicle
positions (rollover, on an incline etc.). The non-return valve prevents the fuel from sloshing back into the filler
pipe after the fuel pump nozzle is shut.
M43TU/52TU (see graphic 2.4, view A)
Description see fuel supply system E38/39, 1.2 functional description, engine fuel supply M52TU.
M52 USA and M73 (see graphics 1.5/1.6)
Description see fuel supply system E38/39, 1.2 functional description, engine fuel supply M52 USA and M73.
M54 (see graphic 1.4, view B and graphics 1.7/1.8)
Description see fuel supply system E38/39, 1.2 functional description, engine fuel supply M54/62TU.
Tank safety valve USA (see graphics 2.6/2.7)
The fuel tank ventilation during refuelling takes place via the refuelling vent line.Because of its large cross-
section, the refuelling ventilation line directs the displaced volume (fuel vapours) at high speed through the
expansion tank to the carbon canister. The activated carbon retains the fuel contained in the fuel vapours. The
cleaned air is discharged to the atmosphere via the evaporation line, the leak diagnosis pump/tank leak
diagnosis module and the dust filter. Ventilation during vehicle operation is done in the same way via the
refuelling tank ventilation line and the service tank ventilation line. The condensed components of the fuel
vapour go from the expansion tank via the left service tank ventilation line back into the fuel tank. The float
valve in the expansion tank is closed by the rising fuel if the tank is overfilled. This prevents the expansion
tank from being overfilled. The roll-over valve on the top side of the expansion tank closes if the vehicle rolls
over. This prevents fuel from spilling into the carbon canister. The carbon canister is regenerated by purging
with fresh air. The engine control unit opens the tank vent valve. This means there is an intake pipe vacuum at
the purge air line. The carbon canister is purged in this way. The fresh air required for this is fed from the
leakage diagnosis pump/the tank leakage diagnosis module and the dust filter. The fuel constituents bound by
the activated carbon are flushed out by the supplied air and directed via the purge air line to the engine for
combustion. This operation is only possible while the engine is running.
Tank safety valve worldwide (see graphic 2.4)
1. The fuel tank ventilation during refuelling takes place via the refuelling vent line which directs the
displaced volume into the fuel filler neck. Instead of the large cross-section refuelling tank ventilation line
(USA), there is a second service tank ventilation line with a small cross-section. There is no float valve.
3. There is no leakage diagnosis pump or tank leakage diagnosis module and dust filter
4. For vehicles in Japan an additional tank ventilation line with a float valve (instead of a refuelling tank
ventilation line (USA)) is integrated into the expansion tank, which is connected to the refuelling-tank
ventilation line (worldwide).This modification is required due to the fuel in Japan with more outgassing
(see graphic 2.5).
Leakage diagnosis for the tank ventilation system USA (see graphics 2.6/2.7)
Description see fuel supply system E38/39, 1.2 functional description, leak diagnosis for the tank ventilation
system USA.
the fuel tank.
Pressure regulator: 3.5 bar
2.4 Fuel supply system E46 M43TU/M52TU/54
2.5 Fuel supply system E46 M43TU/M52TU/M54 Japan

2.6 Fuel supply system E46 M52 USA
2.7 Fuel supply system E46, M54 USA
1. Fuel tank (plastic) 16. Condensate container

4. Suction jet pump 19. Pressure regulator
5. Non-return valve 20. Fuel filter
6. Fuel filler pipe 21. Fuel injection pipe
7. Pressure test line (USA only) 22. Engine control unit
8. Fuel filler cap 23. Tank vent valve
9. Pressure limit valve 24. Intake pipe
10. Run-out protection valve 25. Purge air line
11. Roll-over valve 26. Tank ventilation line
12. Service tank ventilation line 27. Carbon canister
13. Refuelling tank ventilation line 28. Evaporation line
14. Pressure-retaining valve 29. Dust filter
15. Throttle 30. Tank leakage diagnosis module (USA only)
3.2 Functional description (see also graphic 3.4)

Fuel system
The fuel tank contains the surge tank with the fuel pump. The surge tank ensures that the fuel pump is properly
supplied in all vehicle operating conditions. The suction jet pump built into the floor of the surge tank supplies
the surge tank with fuel. The pressure limit valve controls the required pressure to operate the suction jet
pump. The run-out protection valve secures the fuel return line. If the pressure falls if the fuel return line is
damaged or disconnected, the valve closes. This prevents the fuel from running out of the fuel tank in extreme
vehicle positions (rollover, on an incline etc.). The fuel filler pipe is split into two in the fuel tank. This ensures
quicker filling times. The two non-return valves prevent the fuel from sloshing back into the filler pipe after the
fuel pump nozzle is shut.
Description see fuel supply system E38/39, 1.2 functional description, engine fuel supply M54/62.
Tank safety valve USA
condensate tank to the carbon canister. The activated carbon retains the fuel contained in the fuel vapours.
The cleaned air is discharged to atmosphere via the evaporation line, the tank leak diagnosis module and the
dust filter. Ventilation during vehicle operation is done in the same way via the refuelling tank ventilation line
and the service tank ventilation line. The condensed components of the fuel vapour go from the condensate
tank via the service tank ventilation line back into the fuel tank. The roll-over valves of the tank ventilation lines
prevents fuel from getting into the condensate tank in extreme driving condition and positions. The throttle in
the right-hand service tank ventilation line prevents the fuel tank from being overfilled. Once the nominal filling
volume is reached, the roll-over valve closes the refuelling tank ventilation line. Ventilation can only be done
via the service tank ventilation line. If refuelling is continued, the throttle will generate excess pressure in the
fuel tank. This will make filling significantly harder. The pressure-retaining valve in the left service tank
ventilation line limits the excess pressure in the fuel tank.The carbon canister is regenerated by purging with
fresh air. The engine control unit opens the tank vent valve. This means there is an intake pipe vacuum at the
purge air line. This flushes the carbon canister with fresh air via the tank leakage diagnosis module and the
dust filter. The fuel constituents bound by the activated carbon are flushed out by the supplied air and directed
via the purge air line to the engine for combustion. This operation is only possible while the engine is running.
Tank safety valve worldwide
2. There is no tank leakage diagnosis module (see graphic 3.4, view A)
Leakage diagnosis for the tank ventilation system USA
The tank leak diagnosis module (see drawing 3.4 view A) serves to diagnose leakages for the tank ventilation
system within the on-board diagnosis laid down by legislation.
The tank ventilation system is pressurised and the pressure loss is detected in the event of a leak.The tank
leak diagnosis module is activated by the engine control unit and detects the pressure loss by way of the
power The air required for this purpose is supplied via the dust filter. The pressure test line establishes the
connection between fuel tank and fuel filler neck. This enables a leak to be detected in the fuel filler pipe-fuel
tank cap area.
The fuel tank fluid level is measured with a lever sensor. The lever sensor is fastened to the surge tank.
Pressure regulator: 5,0 bar
Operating pressure of the suction jet pump: 1 - 1.3 bar
3.4. Fuel supply system E52
1. Fuel tank (plastic) 15. Expansion tank

2. Fuel pump 16. Anti-flood valve
3. Pressure limit valve 17. Roll-over valve
4. Non-return valve 18. Pressure regulator
5. Fuel filler pipe 19. Fuel filter
6. Fuel tank expansion line 20. Fuel injection pipe
7. Suction jet pump 21. Tank vent valve
8. Run-out protection valve 22. Engine control unit
9. Fuel tank filler cap 23. Intake pipe
10. Fuel delivery line 24. Purge air line
12. Refuelling tank ventilation line 26. Evaporation line
13. Service tank ventilation line 27. Fuel tank leakage diagnosis module
14. Pressure test line (USA only) 28. Dust filter
4.2 Functional description (see also graphic 4.4)

Fuel system
The saddle-shaped fuel tank contains the fuel pump in the smaller, right half. The suction jet pump in the left
fuel tank half pumps the fuel through the fuel tank expansion line to the right side of the fuel tank. The suction
jet pump is operated via the fuel return line. The pressure limit valve controls the required pressure to operate
the suction jet pump. The run-out protection valve secures the fuel return line. If the pressure falls if the fuel
return line is damaged or disconnected, the valve closes. This prevents the fuel from running out of the fuel
tank in extreme vehicle positions (rollover, on an incline etc.). The non-return valve prevents the fuel from
sloshing back into the filler pipe after the fuel pump nozzle is shut.The anti-flood valve on the bottom of the
expansion tank protects the system from overfilling when refuelling. The flood valve is closed by rising fuel in
the refuelling tank ventilation line and excess pressure is created in the fuel tank preventing further filling.
Description see fuel supply system E38/39, 1.2 functional description, engine fuel supply M54/62.
Tank safety valve USA
expansion tank to the carbon canister. The activated carbon retains the fuel contained in the fuel vapours. The
cleaned air is discharged to atmosphere via the evaporation line, the tank leak diagnosis module and the dust
filter. Ventilation during vehicle operation is done in the same way via the refuelling tank ventilation line and the
service tank ventilation line. The condensed components of the fuel vapour go from the expansion tank via
the tank ventilation lines back into the fuel tank. The roll-over valve on the top side of the expansion tank
closes if the vehicle rolls over. This prevents fuel from spilling into the carbon canister.The carbon canister is
regenerated by purging with fresh air. The engine control unit opens the tank vent valve. This means there is
an intake pipe vacuum at the purge air line. This flushes the carbon canister with fresh air via the tank leakage
diagnosis module and the dust filter. The fuel constituents bound by the activated carbon are flushed out by
the supplied air and directed via the purge air line to the engine for combustion. This operation is only possible
while the engine is running.
Tank safety valve worldwide
2. There is no tank leakage diagnosis module and dust filter (see graphic 4.4, view A)
3. There is no pressure test line
Leakage diagnosis for the tank ventilation system USA
Description see fuel supply system E52, 1.2 functional description, leak diagnosis for the tank ventilation
system (USA)
the fuel tank.
4.3 Operating data, fuel system
Pressure regulator: 3.5 bar
4.4. Fuel supply system E53
5. Fuel supply system E38/39 diesel
1. Fuel tank (E38 steel, E39 plastic) 17. Dust filter

4. Suction jet pump 20. H-piece (M47/67)
5. Run-out protection valve 20A 5x distributor (M57)
6. Pressure limit valve 21. Power distribution box injection pump (M47)
7. Refuelling tank ventilation line 21A High pressure pump (M57/67)
8. Non-return valve 22. Gear pump (M67)
9. Fuel filler pipe 22A. Inline pump (E38/39 M57)
10. Fuel filler cap 23. Fuel filter
11. Fuel tank expansion line 24. Fuel injection pipe (M57/67)
12. Service tank ventilation line 25. Injector nozzle
13. Service tank ventilation line 26. Manifold (M67)
14. Auxiliary heater 27. Bimetal valve
15. Expansion tank 28. Fuel cooler
16. Roll-over valve 29. Pressure limit valve (M57)
5.2 Functional description (see also graphics 5.4/5.5/5.6/5.7)
Fuel system (see graphics 5.4/5.5/5.6/5.7)
Description see fuel supply system E38/39, 1.2 functional description, fuel system.With the following
differences:
1. Both suction jet pumps are operated via the fuel delivery line.
2. An additional electric auxiliary heater with its own supply line from the fuel tank.
3. There is no non-return valve in the filler pipe (E38 only)
M47 (see graphic 5.4)
The fuel is routed from the electric fuel pump via the fuel delivery line and the fuel filter to the power distribution
box injection pump. The distribution box injection pump supplies the respective injector nozzle.The reverse
flow from the fuel injector and the power distribution box injection pump goes into the bimetal valve. The
bimetal valve divides the amount the fuel return as a function of the fuel temperature.At low fuel temperatures
the majority of the fuel goes back into the fuel delivery line before the fuel filter. In this way, the fuel is heated
faster at low outdoor temperatures.At high fuel temperatures the majority of the fuel goes via the fuel cooler
and the fuel return line back into the fuel tank. Thus, excessive heating of the fuel is avoided at high outside
temperatures.Large heated quantities of return fuel may occur in extreme operating conditions such as uphill
driving or trailer towing. In this event a small amount of fuel will be sent directly into the fuel delivery line via the
throttle in the H-piece. This measure prevents excessive fuel heating in the fuel tank.
M57 (see graphics 5.5/5.6)
The fuel is routed from the electric fuel pump via the fuel delivery line, the inline pump and the fuel filter to the
high pressure pump. The high pressure pump supplies the injector nozzles with fuel via the fuel injection
pipe.The inline pump generates the required primary fuel pressure for the high pressure pump. This primary
pressure is kept constant by the pressure-limiting valve in the engine circuit.The reverse flow from the fuel
injector and the high-pressure pump goes into the bimetal valve. The bimetal valve divides the amount the fuel
return as a function of the fuel temperature.At low fuel temperatures, the majority of the fuel flows via the 5x
distributor back into the fuel delivery line before the inline pump. In this way, the fuel is heated faster at low
outdoor temperatures.At high fuel temperatures the majority of the fuel goes via the fuel cooler and the fuel
return line back into the fuel tank. Thus, excessive heating of the fuel is avoided at high outside
temperatures.Large heated quantities of return fuel may occur in extreme operating conditions such as uphill
driving or trailer towing. In this event a small amount of fuel will be sent directly into the fuel delivery line via the
throttle in the 5x distributor piece. This measure prevents excessive fuel heating in the fuel tank.
The fuel is routed from the electric fuel pump via the fuel delivery line, the fuel filter and the geared pump to the
high pressure pump. The high pressure pump supplies the injector nozzles with fuel via the manifold and the
fuel delivery lines.The geared pump, which is flanged directly to the high pressure pump, generates the
required primary fuel pressure for the high pressure pump. The reverse flow from the fuel injectors and the high
pressure pump goes into the bimetal valve (for functional description of the bimetal valve and H-piece see
M47). The non-return valve in the H-piece blocks the fuel delivery preventing fuel reverse flow. This prevents
pressure drop during times of high fuel requirement.
Tank safety valve
The fuel tank ventilation during refuelling takes place via the refuelling vent line in the fuel filler neck.During
operation, the expansion tank and dust filter areas vented from the fuel tank via the service breather lines.The
condensed components of the fuel vapour go from the expansion tank via the left service tank ventilation line
Description see fuel supply system E38/39, 1.2 functional description, determining fuel tank level.
Operating pressure of the fuel pump: 0.4 bar
5.7 Fuel supply system E38, M67
6. Fuel supply system E46 diesel
1. Fuel tank (E38 steel, E39 plastic) 14. Service tank ventilation line
2. Fuel pump 15. Expansion tank
3. Surge tank 16. Roll-over valve
4. Suction jet pump 17. Power distribution box injection pump (M47)
5. Fuel tank expansion line High pressure pump (M57)
6. Run-out protection valve 18. Inline pump (E38/39 M57)
7. Fuel filler pipe 19. Fuel filter
8. Fuel filler cap 20. Fuel injection pipe (M57)
9. Refuelling tank ventilation line 21. Injector nozzle
10. Fuel return line 22. Bimetal valve
11. Fuel delivery line 23. Fuel cooler
12. H-piece (M47) 24. Pressure limit valve (M57)
13. Service tank ventilation line
6.2 Functional description (see also graphics 6.4/6.5)

Fuel system (see graphics 6.4/6.5)
Description see fuel supply system E46, 2.2 functional description, fuel system.With the following differences:
1. The suction jet pump is operated via the fuel return line.
2. There is no non-return valve in the filler pipe.
3. There is no pressure limit valve in the fuel tank
Description see fuel supply system E38/39 diesel M47, 2.2 functional description, engine fuel supply .
Description see fuel supply system E38/39 diesel M57, 2.2 functional description, engine fuel supply.With the
following differences:
1. The H-piece replaces the 5x distributor.
2. The fuel return line from the bimetal valve is routed directly before the inline pump
Tank safety valve (see graphics 6.4/6.5)
Description see fuel supply system E38/39 diesel M57, 2.2 functional description, engine fuel supply.With the
following difference:- The dust filter is omitted.
Description see fuel supply system E38/39, 1.2 functional description, determining fuel tank level.
Operating pressure of the fuel pump: 0.4 bar
18 02 03 (062)
Exhaust standard EURO 4 and E‐OBD for diesel engines
M47TU, M57TU
Introduction
Exhaust emission standard EURO 4 is mandatory across Europe from 01.01.2005 for newly homologated
vehicle types ('homologation' = registering a production vehicle in the international registrations list). Exhaust
emission standard EURO 4 is mandatory from 01.01.2006 for the registration of all new vehicles. Exhaust
emission standard EURO 4 further reduces the limit values for pollutants in exhaust gas. [more ...]
In addition, in Europe from 01.01.2004 the European on-board diagnosis (E-OBD) is legally required for all
diesel engines in passenger cars. [more ...]
This BMW Service Technology also includes a list of fault codes for the E-OBD. [more ...]
The 4-cylinder diesel engine M47TU is installed in the E46 (RHD since 09/2003, LHD since 03/2004) with manual
gearbox and exhaust emission standards EURO 4. In 03/2004 exhaust emission standards EURO 4 was also
implemented in the 6-cylinder engine M57TU. [System overview ...]
On the M57TU the E60/E61 was equipped for the first time with a diesel particle filter. The diesel particle filter
separates out the soot particles in the exhaust gas with a high level of filter performance (> 95 %). The
nitrogen oxide emissions do not affect the diesel particle filter. The nitrogen oxide pollutant emissions are
reduced by measures inside the engine. The new diesel particle filter developed by BMW does not deliver the
customer any disadvantages relating to:
Scope of maintenance work
Fuel consumption
Engine power
Nose comfort
The diesel particle filter is currently designed for approx. 200,000 kilometres (monitoring by means of Condition
Based Service). The use of a fuel additive in regeneration of the diesel particle filter is not necessary (fuel
additive reduces the ignition temperature of the soot).
To comply with exhaust emission standard EURO 4, the following components in the M47TU/M57TU are new or
have been modified:
Oxygen sensor
A Lambda oxygen sensor is necessary for compliance with exhaust-gas limit values.
The oxygen sensor is required for the quantity mean value adaptation of the injectors.
The Lambda oxygen sensor measures the fuel‐air ratio. In the event of deviations, the DDE adapts the
exhaust-gas recirculation rate to suit the change in air/fuel ratio.
[more ...]
Injector
The injector characteristic map is adapted to suit the fuel injection rate.
A design change has given the injection system a constant characteristic curve. That means that
changes in the injection period can directly impact changes in the fuel injection rate.
[more ...]
Charging pressure actuator (electrical actuator drive on the exhaust turbocharger)
The exhaust turbocharger has a variable turbine geometry (VNT = ”variable turbine geometry” from the
English term ”Variable Nozzle Turbine”). To achieve compliance with exhaust emission standard EURO 4
an electrical charging pressure actuator now adapts the variable turbine geometry (previously, an
electromagnetic pressure converter adjusted the variable turbine geometry).
By virtue of the increased adjustment speed and the more rapid response to changes, greater precision
is achieved in respect of charging pressure control.
[more ...]
Cylinder head and piston
The cylinder head has a geometrically revised swirl port and swirl port.
To improve mixture preparation, the shape of the piston recess has been modified. This has also give
rise to a change in the coolant duct in the piston.
[more ...]
Exhaust gas recirculation cooler
The exhaust-gas recirculation cooler is now longer. The exhaust-gas recirculation cooler therefore has
increased cooling power. With the new exhaust-gas recirculation cooler, the exhaust-gas temperature is
reduced by approx. 100 °C (in the driving cycle for EURO 4).
[more ...]
Diesel particle filter (only M57TU in the E60, E61)
The diesel particle filter has a catalytic coating which absorbs soot particles from the exhaust gas.
Continuously, the stored soot particles are incinerated once the exhaust gases reach a temperature of
approx. 350 °C.
Cyclically, the stored soot particles are incinerated once the exhaust gases reach a temperature of
approx. 600 °C.
[more ...]
When the diesel particle filter is used, additional components are required for the Digital Diesel
Electronics (DDE):
Throttle valve
Under certain operation conditions, the throttle valve throttles the intake air. In combination with 1 to
2 post injections, this leads to an increase in the exhaust-gas temperature (regeneration of the
diesel particle filter). [more ...]
Exhaust backpressure sensor upstream of the diesel particle filter, exhaust temperature sensor
upstream of catalytic converter and exhaust-gas temperature sensor upstream of the diesel
particle filter
With the exhaust backpressure sensor, the level of load on the diesel particle filter is calculated
when the vehicle is in motion. Whenever the diesel particle filter has built up too many soot
particles, a regeneration cycle is initiated.
As a further parameter, the exhaust-gas temperature is measured upstream of the diesel particle
filter. Measurement of the exhaust back pressure by the exhaust backpressure sensor is not
sufficient in its own right (load-dependency).
From both these signals, the DDE calculates the precise loading for the diesel particle filter.
The exhaust temperature sensor upstream of catalytic converter monitors the exhaust-gas
temperature upstream of the oxidation catalytic converter. Regeneration of the diesel particle filter
cannot take place until an exhaust-gas temperature of approx. 350 °C.
[more ...]
Leaktight swirl flaps
The M57TU has totally leaktight swirl flaps (electrically activated in the E46, otherwise activated by
vacuum). This does not give rise at the lower end of partial load operation to any leakage around
the swirl flaps, making an increase in swirl possible. In addition, with the electrical activation function,
a tremendously wide variety of intermediate settings on the swirl flap can be achieved.
System functions
Despite component tolerances and influences on components over their operating time (e.g. wear), careful
attention must be paid to these points: The emissions threshold values must be complied with to a sufficiently
large safety distance. More extensive emission-related fluctuations can be anticipated in the first instance from
the following components:
Injectors
Hot film air mass meter
Rail pressure sensor
The tolerances of the components and the influences over the operating time on component must be
compensated for. For compensation on the DDE (Digital Diesel Electronics) the following system functions
exist:
Injection quantity compensation
Zero-quantity adaptation
Mean quantity adaptation
Regeneration of the diesel particle filter (only M57TU in the E60, E61)
Injection quantity compensation

Injection quantity compensation involves the definition of correction values for pre-injection and main
injection of an injection system. The injection quantity compensation process is conducted at the end of
the production process.
The tolerances given to the injectors on manufacture mean that the actual injected fuel quantity deviates
slightly from the calculated fuel quantity. The extent of this deviation is established after production for
every injector by measurements, conducted across several operating points.
From these measurements, an adjustment value (code) is generated for each injector.
The structure of the alphanumeric code depends on the exhaust emission standard applicable to that
engine:
Exhaust emission standard EURO 3: six-digit (e.g. 78SNGT)
Exhaust emission standard EURO 4: seven-digit (e.g. 88S66NB)
During vehicle assembly, after installation of the DDE control unit, the adjustment value of each installed
injector is stored in the DDE control unit. The adjustment values are allocated to the individual cylinders
according to the installation of the injectors. With these adjustment values, the DDE control unit corrects
the calculated fuel injection rates slightly and, in this way, it reduces the cylinder-specific deviation of the fuel
injection rate.
Whenever injectors have to be replaced, it must be ensured that the stamped alphanumeric code of each
injector is assigned to the correct cylinder in the DDE control unit.
The BMW diagnosis system has the service function ”Injection quantity compensation”. With this service
function, the code for each cylinder can be changed and stored on the DDE control unit.
For cylinders for which no new adjustment value is entered, the old adjustment value is retained in the DDE
control unit. Injection quantity compensation must also be performed if the DDE control unit is replaced and
communication was no longer possible with the old control unit.
The codes for the injectors installed must be read off and stored in the DDE control unit.
Zero-quantity adaptation
Zero-quantity adaptation is the adaptation process which is used after the running-in phase (approx.
1500 km) for every single injector to assure the presence of a defined level of pre-injection.
To achieve compliance with exhaust emission standard EURO 4, precise metering of the very small fuel
injection rate is required for pre-injection purposes.
Due to the deviation for the fuel injection rate over the operating time, the zero-quantity adaptation is
performed continuously by the DDE control unit.
For every cylinder in coasting (overrun) mode, a small quantity of fuel is injected. This quantity is then
varied until the desired torque rating is detected by the DDE. To calculate the torque rating, the irregular
rotation of the crankshaft is incorporated in the equation. This irregular rotation is recorded on the
crankshaft sensor.
This enables the DDE to detect the activation duration after which the cylinder starts to operate. The
quantity of fuel injected during the zero-quantity adaptation period is used by the DDE as a correction value
for the gearshift map of the pre-injection process.
The zero-quantity adaptation process switches from one cylinder to another in each overrun phase at:
engine speed 1500 to 2500 rpm (engine at operating temperature)
The zero-quantity adaptation has no impact on fuel consumption because only a small quantity of fuel is
injected into each cylinder (approx. 1 mm3).
Mean quantity adaptation

Mean quantity adaptation is the adaptation process at which the air/fuel ratio is corrected (partial load
range). This correction is performed by adapting the amount of air by means of the exhaust-gas recirculation
valve.
Whereas no additional components are required for the injection quantity compensation and for the zero-
quantity adaptation, an oxygen sensor is required for the mean quantity adaptation. The oxygen sensor is a
broadband oxygen sensor with a constant characteristic curve.
The mean quantity adaptation is not a rapid control operation, but is instead an adaptive learning procedure.
An oxygen sensor deviation is ”learned” in a characteristic map and stored for a sustained period in the DDE
control unit (EEPROM).
The characteristic map must be reset (deleted) in EEPROM if any of the following components is replaced:
Hot film air mass meter
Injector
Rail pressure sensor
To reset the characteristics map, the BMW diagnosis system offers the service function of ”mean quantity
adaptation”.
Regeneration of the diesel particle filter (only with M57TU in the E60, E61)
The soot load in the diesel particle filter is established by the DDE from the engine operating points.
Regeneration of the diesel particle filter can be continuous and/or cyclical.
Continuous regeneration:
In operating ranges at which the exhaust-gas temperature exceeds the ignition temperature of the
soot (> 350 degrees Celsius), the soot particles are converted directly. This involves the soot
particles being converted by a process of slow oxidation into carbon monoxide (CO) and carbon
dioxide (CO2).
The oxidation agent is the nitrogen dioxide present in the exhaust gas (NO2). This nitrogen dioxide is
formed from the nitrogen monoxide (NO) in the oxidation catalytic converter.
If the exhaust-gas temperature is not hot enough for this process, the soot particles are initially
collected in the diesel particle filter and are then incinerated the next time that the exhaust-gas
temperature increases.
Cyclical regeneration:
If the driving style does not permit continuous regeneration of the diesel particle filter (e.g. long,
sustained partial load operation in urban traffic and low exhaust-gas temperature), targeted
regeneration is initiated.
This process is controlled by signals from the exhaust backpressure sensor and two exhaust-gas
temperature sensors. Cyclical regeneration runs like continuous regeneration without significant
implications on drivability.
Depending on the load condition of the engine, regeneration can take the form of targeted throttling of
intake air in conjunction with 1 to 2 post-injections. This raises the exhaust-gas temperature to approx..
600 degree Celsius. The residual oxygen in the exhaust gas (O2) enables soot to be burned off. The
regeneration of the diesel particle filter can take several minutes. The interval stages for regeneration
depend on the operating conditions of the vehicle over its last 500 kilometres. At high exhaust-gas
temperatures, there is less soot buildup as a result of continuous incineration of the soot particles.
In addition, every 700 to 2500 kilometres (depending on driving profile), regeneration of the diesel
particle filter can be initiated. In the event of failure of the exhaust backpressure sensor or of one of
the exhaust-gas temperature sensors, the diesel particle filter is regenerated every 500 kilometres.

Observe the following information for service:
Diagnosis: [more ...]
Car & Key Memory: ---
No liability can be accepted for printing or other faults. Subject to changes of a technical nature
32 01 99 (503)
Kinematics diagnosis system and environment
BMW KDS (Beissbarth)
Table of contents
1. Foreword
1.1 Objective
1.2 Further development of the BMW kinematics diagnosis system
1.3 Technical data
1.4 Delivery specification
1.5 Required accessories
1.6 Advisable accessories
2. Measuring options with the BMW KDS
2.1 Front Axle
2.2 Rear Axle
2.3 Other rmeasuring options
3. System description
3.1 BMW KDS 1, based on the ML4000 from Beissbarth
3.2 Computer
3.3 Graphics pad
3.4 Equipment cabinet
3.5 Remote display
3.6 Measuring pickup with image sensor (CCD camera)
3.7 BMW quick-release brackets
3.8 Rotational / sliding supports
3.9 Sensor tips
3.10 Spoiler adapter
3.11 Quick-clamping units
3.12 Retaining claws
4. Work bay
4.1 Environment
4.2 Prerequisite for measurement
4.3 Measuring tolerance
4.4 Levelling of measuring point
5. Chassis-specific terms
5.1 Toe difference angle
5.2 Camber
5.3 Toe
5.4 Castor
5.5 Geometrical driving axis / symmetrical axis
5.6 Wheel offset angle
5.7 Kingpin offset / kingpin radius
6. Wheel suspension
6.1 Rigid axle
6.2 Independent suspension
7. Wheel alignment / procedure
7.1 Measuring options
7.2 Preparatory work:
7.3 Incoming / outgoing wheel alignment
7.4 Printout of the data
8. Special features
8.1 Wheel alignment with non-selective access
8.2 System setting
9. Comparison, BMW KDS (Bosch - Beissbarth)
10. Change in operation (menu)
10.1 Master key with display
10.2 Summary operating instructions
10.3 Display support
11. Software updates / nominal data
11.1 Preconditions
11.2 Procedure (Beissbarth)
11.3 Procedure (Bosch)
12. Creating, copying and editing nominal data
12.1 Copying
12.2 Creating
13.3 Editing
13. Special functions
13.1 Customer button for printer protocol
13.2 Adjustment options
13.3 Turntable test
13.4 Viewing and deleting customer entries from the database
14. Internal program change
15. Error
15.1 Tyre fault

15.2 Front axle fault
15.3 Rear axle fault
1 Preface
1.1 Objective
The complexity of wheel alignment as a topic has increased. This BMW Service Technology document is
therefore intended to achieve several objectives:
- Compiling guidelines for working with the BMW KDS.
- Getting to grips with the technology of wheel alignment on modern vehicles and clarifying any questions
that arise.
- Transparency and clarification of different terminology.
- Clarification of fault causes from the past, so that these can be avoided in future after studying this paper.
- Prerequisites for safe dealings with BMW KDS.
- The BMW kinematics diagnosis system (KDS) forms an integral element of systems-based philosophy in
relation to automotive technology. This provides the peace of mind of being able to work rationally and in a
BMW-compliant manner, and the certainty of being prepared for future technological developments. With
regard to precision and performance in the area of wheel alignment and chassis adjustment, BMW has
done the best it can with what is technologically feasible: The BMW kinematics diagnosis system (KDS).
- The BMW kinematics diagnosis system from Beissbarth is more than just a further development of
conventional axle alignment equipment. It sets new dimensions in terms of precision, performance, speed
and handling. Guarantees for the perfection upon which BMW customers count in their dealings with BMW
Service.
- Ride comfort, driving safety and tyre wear depend to a large extent on perfect interaction with vehicle
kinematics. BMW is constantly delivering new generations of chassis and suspension to the market, each
of which is superior and/or even closer to perfection than its predecessor. That means that there are fewer
kinematic adjustment points on the chassis and suspension and even tighter specified tolerances with
regard to wheel alignment and adjustment.
- Through the use of the multilink rear axle and the E36, the previously recommended electronic wheel
alignment equipment was no longer suitable for BMW chassis alignment checks. This related to the
measuring procedure as well as to the measuring accuracy. The generation of equipment approved with
the introduction of the E36 range is still able today to satisfy all the requirements imposed on modern
wheel alignment equipment, including the use of the latest computer technology.
- For wheel alignment purposes, only the BMW kinematics diagnosis systems from Beissbarth and Bosch
may be used.
1.3 Technical data
1. Display - 17 inch graphics screen with high-resolution
graphics (640x480 pixels with 256 colours)
2. Teletext - in each programmed national language
3. Wheel sizes - 12"...20"
4. Vehicle memory capacity - unlimited
5. Turntables - Load-carrying capacity 1000 kg, angle of rotation ±

360°, 450 x 450 x 50mm (L x B x H), sliding range ±
50 mm, weight 18 kg
6. Sliding supports - Load-carrying capacity 1000 kg, angle of rotation ±

65 mm, weight 17 kg
7. Electrical connection - 100...115 V / 220...240 V 50/60 Hz, 0,5 kW (other

connections on request)

1 PC display element with graphics screen, graphics panel, equipment cabinet, small or large including
automatic charging station, DIN-A4 dot matrix printer
4 Pickup with CCD camera technology and infrared data transfer, with installed voltage supply
1 Wiring harness (comprising 4 cables)
1 Brake tensioner
1 Steering wheel lock
2 Electronic precision turntable supports with integrated sensor and without approach ramp
2 Sliding supports without approach ramp
4 BMW quick-release units comprising a locating bell housing P8-68 and quick-release bracket P267 01, incl.
coated retaining claws
1 Operating instructions for BMW KDS (8 languages)

1 BMW software and the BMW nominal vehicle data with adjustment images as well as texts for
measurement preparations
2 Locking rods for positioning the vehicle
1 Set of sandbags for specified loading
4 Quick-clamping units
2 Set of collision plates
1 Remote control / display
1 Transport carriage (for ballast pockets, turntables and sliding plates, and 4 quick-release brackets)
2 Measuring options with the BMW KDS
2.1 Front axle
- Toe-in (individual wheel and total toe-in relative to the geometrical driving axis)
- Camber (when driving straight ahead)
- Wheel offset (relative to the left front wheel)
- After-run, steering axis inclination and toe difference angle
2.2 Rear axle
- Toe-in (individual wheel and total toe-in relative to the central plane of the vehicle's longitudinal axis -->
previously known as the symmetrical axis)
- Geometrical driving axis
- Camber
- Wheel offset, rear
- Wheelbase difference
- Lateral offset, right
- Lateral offset, left
- Track width difference
- Axial offset
3.1 BMW KDS 1, based on the ML 4000 from Beissbarth
The KDS 1 is available without surcharge in a choice of two design versions:
1. Mobile workstation
2. Mobile compact cabinet
The larger workstation provides a small storage space for accessories, whereas the compact cabinet is mobile
and is ideal for confined working areas. Both versions are available as a wireless measuring system (infrared).
In terms of measuring technology, the only difference between these two systems is in their handling and their
upgrade options. In both these versions, the four pickups are stored in integrated inserts with battery charge
points. Following the automatic charging process, the accumulators on the pickups deliver enough power for
10 hours of continuous operation.
3.2 Computer
KDS system 1 comprises tried-and-tested and thoroughly reliable industrial components. The
computer is an IBM-compatible 32-bit Intel processor with CD drive, of the kind commonly used in the
PC sector.
3.3 Graphics pad
All functions are depicted graphically on a ”Symbol" pad. The

pad is protected beneath a Plexiglas panel. This is easy to
replace whenever major design changes are required. The
user interface has no membrane and is therefore safely
protected against damage. The main functions are enabled by
clicking the symbol with the sensor probe.
The PC with graphics monitor and pull-out operating pad,

mountings for the pickups, the remote control and the DIN-A4
printer are integrated on the workstation. The charging station
is located in the cabinet and can also be connected to the
pickups and remote control unit by plug-in cables (operation
with simultaneous charging of the accumulators / rechargeable
batteries).
3.5 Remote display
A wireless remote display unit can be provided on request. The

remote control buttons are only enabled during the
measurement and setting process (not in response to
customer input, choice of vehicle, processing of nominal data
etc.). The following displays are supported by the remote
display facility:
- Measured value with nominal/actual variance comparison and tolerance bar

- Touchscreen icon for touch-sensitive routines
- Live overview of toe-in / camber values with nominal / actual comparison
- Rims, lateral runout compensation
3.6 Measuring pickup with image sensors (CCD cameras)

Each of the measuring pickups is equipped with two image
sensors and its own processor for wireless infrared
transmission with integrated accumulators for automatic
measurement. Advantages:
- No temperature deviation
- Very high measuring resolution (theoretically, toe-in could be measured in seconds of an angle).
- Single toe-in range of more than ± 9 degrees relative to constant screen display of toe-in during the
replacement of track rod ends
- Exact system precision, i.e. with measurements on the vehicle following rim lateral runout
compensation: an accuracy of 2 minutes of angle for toe-in and camber
- BMW quick-release brackets for precise mounting of measuring pickups and measurement without
compensation of lateral runout on rims.
- Note: Quick-release brackets potentially available,, e.g. from older F1600 or ML-3000 models, must not
be used with the BMW KDS.
- Electronic precision turntables (rotational supports) for the front wheels with integrated sensor (360
degrees all-round measuring range)
- Robust sliding supports for the rear wheels with a swivelling / rotating upper plate.
- Accessories: Cover for aluminium rotational supports / turntables
3.9 Sensor probes

- From April 1993, a new BMW light-alloy wheel (styling No. 18) has been available as a BMW optional
accessory. During vehicle alignment checks on these wheels, new sensor probes are required for the
quick-release mountings on the recommended wheel alignment equipment.
- On recent deliveries of KDS 1, the new sensor probes are included in the delivery specification (order
number: BS 90 19 11).
3.10 Spoiler adapters
- On vehicles with very deep spoilers, it is possible for the measuring beam between the measuring
pickups to get interrupted. This is particularly true of the transverse front axle.
- In this case, the spoiler adapter acts as a connecting member between the measuring device holder
and the measuring pickup. This causes the measuring pickup to be located 50 mm lower, thereby
enabling the measuring beam to pass freely below the spoiler.
3.11 Quick-release mountings
- Quick-release mountings for the wheel alignment of other vehicles with compensation of lateral runout
on rims.
- Wheel rims without sensor bore holes (wheel rims for BMW vehicles made my other manufacturers)

- The versatile retaining claws and the rubberised retaining claws enable an extremely wide and varied
range of clamping variants to be used for the measuring equipment holder, even on exotic, i.e.
extremely unusual, light-alloy rims.
4. Workbay
4.1 Environment
Description: Prerequisites:
All the vehicle hoists currently recommended by
BMW (cf. Workshop Equipment - Planning - Wheel alignment pits
Documentation, issue 11) for wheel alignment
equipment comply with the requirements for BMW
KDS. - Telescopic mast vehicle hoists with lowering
facility
- 2-stamp vehicle hoists with lowering facility
- Repair statuses with lowering facility
The BMW KDS does not impose great demands on

its installation location. The device can be used over - One measuring station (approx. 4.5 m x 7.0 m).
inspection pits or on vehicle hoists (i.e. workshop
ramps).
- The rotational supports ('turntables') must be
bolted to the vehicle hoist
The locating surfaces for rotational and sliding plates must not
exceed the maximum difference in height described below:
- from left to right ± 0.5 mm

- from front to back ± 1.0 mm
- diagonally ± 1,0 mm.
Note:
A height difference between turntables of ± 2 mm from left to right gives rise to a measuring error
with camber of 4,8°.
For comparison: The camber tolerance on the E36 is ± 10'. Tyre tread difference or different
inflation pressures give rise to measuring errors on the same magnitude.
4.2 Prerequisites for the wheel alignment check
During the wheel alignment check, the front and rear wheels need to be standing on the rotational and sliding
supports to enable all wheel suspension points during the touch-sensitive routine and the adjusting procedure
to remain free of torsional stresses. This demonstrates the need for the rotational and sliding supports for the
various wheelbases and track widths on the candidate vehicle for the wheel alignment check to be relocated.
The full range of measuring tolerance are system tolerances. That means that the total of all individual
tolerances yields the value identified in the argumenter. Example - camber: Quick-release bracket + measuring
pickup + computer = 1' with a measuring range of ± 3° (all BMW vehicles lie within this measuring range).
4.4 Measuring station levelling
The manufacturers of BMW KDS (Beissbarth / Bosch) are able to check the alignment of the measuring station
to the required level of precision, using levelling devices to do so. Bars or hose-type water scales are not
suitable. Vehicle hoists must be under load when being levelled to ensure that due account is taken of the
uneven deflection in vehicle rails.
Important!
A specialist operator must be involved in the setup work on each vehicle hoist (a member of the
manufacturer's Service Product Support staff).
The toe difference angle (a) is the angle setting of the inner
cornering wheel relative to the outer cornering wheel when
negotiating a bend in the road. Steering is designed in such a
way that the relative angular positions of wheels change as
steering lock progresses.
In ideal situations, the wheel axes intersect at Point D in every
steering position (except for straight ahead).
5.2 Camber
Camber is the inclination of the wheel from the perpendicular.
5.3 Toe-in
Toe-in is the reduction in distance of front of front wheels to

rear of front wheels. Toe-in prevents the wheels from moving
apart when driving (wobbling and scuffing).
5.4 After-run
After-run is the inclination of the kingpin viewed from the side
and relative to direction of travel. The line through the centre
point of the spring strut support bearing and the control arm ball
joint corresponds to the ”kingpin”.
5.5 Geometrical driving / symmetrical axis
- (1) The geometrical driving axis is the angular intersection point from total toe-in on the rear wheels.
- (2) The symmetrical axis constitutes the centreline between front and rear axles.
The wheel offset angle is the angular deviation in the

intersection line of wheel contact points at a line drawn at 90°
to the geometrical driving axis. The wheel offset angle is
positive when the right wheel is displaced towards the front and
negative when it is displaced towards the rear.
The kingpin offset / kingpin radius is the distance from the

centre of the wheel contact face to the intersection point of the
extension of the kingpin axis.
6. Wheel suspension
Wheel suspension includes the components which connect the wheel to the mostly load-bearing floor pan
components on the body which guide the vehicle in the desired direction. This connection involves axles or
comparable construction elements, guided by trailing arms. The type of wheel suspension is one of the
determining factors governing the driving characteristics of a vehicle. A distinction is made between two main
groups: 1. The rigid axle and 2. The independent suspension.
6.1 Rigid axle
Description Advantages Disadvantages

On the rigid axle, both wheels or No changes in camber and toe-in Non-driven rear axles can also
pairs of wheels are connected by occur during suspension action. receive negative camber and this
means of a rigid axle body. Every This means: low tyre wear and increases tyre wear.
change in a one wheel is good directional stability.
transferred to a greater or lesser
extent to the other one. If a rigid
axle has been installed, it is now
only ever as a rear axle. This is
sharp contrast to trucks and buses
where they are used frequently.

Based on the modern technology Independently suspended wheels Depending on design, during
standard independent suspension do not influence one another. suspension action, changes can
is available on the front and rear occur in camber, toe-in, track width,
axles of BMW vehicles. This after-run and wheelbase.
development was prompted by
inertia mass because a reduction
in unsprung masses improves
wheel and ground contact,
enabling the wheel to maintain
better traction. The tracking of
independently suspended wheels
requires transverse links and
trailing arms which can be called
upon to absorb occasional high
levels of longitudinal and lateral
forces.
7. Wheel alignment / test procedure
The next section itemises all the measuring options and values in an at-a-glance list (FA = front axle, RA = rear
axle).
Measuring options Measuring accuracy with measuring range Total measuring

range
Total toe-in (FA + RA) ± 2' ± 2° ± 18°
Single wheel toe (FA + RA) ± 2' ± 2° ± 9°
Camber (FA + RA) ± 1' ± 3° ± 10°
Wheel offset (FA) ± 2' ± 2° ± 9°
Geometrical driving axis ± 2' ± 2° ± 9°
Castor ± 4' ± 18° ± 22°
Steering axis inclination ± 4' ± 18° ± 22°
Toe difference angle ± 4' ± 20° ± 20°
Maximum steering angle (FA ) ± 4' ± 60° ± 300°
Maximum steering angle (RA ) ± 4' ± 9° ± 9°
After-run correction range ± 4' ± 7° ± 10°
Note:
The details for the measuring accuracy only apply when using precision rotational and sliding
supports together with BMW quick release brackets.
Before the measurement can commence, preparatory work is required at the measuring station and on the
vehicle (see BMW KDS, operating instructions). This preparatory work includes:
- Ease-of-movement of rotational and sliding plates
- Alignment of rotational and sliding supports to suit track width and wheelbase
- Driving of vehicle centrally onto the supports
- Apply parking brake
- Remove locking pins from the supports to prevent torsional stresses in the chassis and suspension when
subjecting the vehicle to load.
- Check the wheel rim and tyre size, tread depth, inflation pressure, steering backlash, wheel bearings and
condition of the suspension and shock absorbers
- Secure measuring device bracket to the wheels
- Load vehicle acc. to BMW KDS specification
- Apply sudden load to vehicle with brakes released to obtain a stable centre position.
- Secure the service brake by applying the brake tensioner
7.3 Input / output measurement
This measurement can be conducted as a program-guided measurement check, just like any subsequent
adjustment work and the ensuing outgoing alignment check. The sequence of chassis and suspension
measuring points to be called up and checked by the systems software. The individual procedural steps cover:
- driving in a straight line to obtain an accurate record of the toe-in and camber value for the rear axle
- touch-sensitive routine to determine after-run, steering axis inclination and toe difference angle
- Recording of toe-in and camber of front axle (prior to this, set the steering centrepoint)
- touch-sensitive routine to measure the maximum steering angle on left and right sides
- Checking the measuring value summary with nominal / actual comparison of all measured values.
The report printout from the integrated DIN-A4 printer is subdivided into three areas:
- Headers with customer and vehicle identification data --> here, the customer data entered before the start
of measuring work are printed out together with the vehicle data.
- Centre section with vehicle data --> these include brand, type, model and model year of the vehicle, as
defined during selection of the nominal data record. Furthermore, this section involves printing out the
previously measured values for ride height, inflation pressure and tread depth.
- The final section with all chassis and suspension measuring values comprises 3 columns: incoming wheel
alignment check, nominal values and outgoing measurement. The measured values are recorded
separately in these 3 columns.
8. Special features
During wheel alignment checks with non-selective access, the selection and sequence of measuring points
can be made in any desired order. When doing this, the following points must be observed in order to achieve
the correct measuring results:
- Carry out all work as defined during the program-guided wheel alignment check.
- Before the alignment check of toe-in and camber values on the rear axle, the steering must be set in its
'straight-ahead' position to ensure that it is aligned with the vehicle's centre axis.
- Prior to the alignment check of individual toe-in values on the front axle, the steering wheel centre position
needs to be determined to ensure that the steering wheel is in its correct position.
8.2 System settings
The following settings only need to be entered and set once: language, display format, date/time, promotional
text, remote control with display, selection of rotary plate and printer setting. These remain saved in memory.
Bosch Beissbarth
Recording of measuring values Infrared Image sensor
Data transmission Cable Infrared / cable
Voltage supply to the pickups Cable Accumulator / cable
Master key Infrared Infrared
Master key with measuring value Cable Infrared
display
Nominal data memory Disk Hard disk
Measuring value memory Always the last vehicle measured unlimited vehicle memory capacity
Operating system --- MS-DOS
Languages English and one language on order EN, DE, NI, SV, IT, FR, SP (other
languages on request)
Update 3.5" diskette 3.5" diskette from TIS/DIS
Monitor 20" 17"
Computer --- Pentium
Drives 2 x diskette 1 x diskette, 1 x CD-Rom
10 Change in operation (menu)
The process of enabling the master key with display is described in the following procedural steps:
1. in the special functions (button ”S"), call up the ”Service" menu
2. In the”Service" menu, call up the ”Master key" submenu
3. In the ”Master key" submenu, select the ”Master key with display" point - this is a once-only setting.
Important!
On devices without master key, this setting must be set to ”No master key".
10.2 Summary of operating instructions
1. Switch on the master key by pressing the ”ON" button (it is permissible to switch this on during the
alignment check). The title screen then appears on the LCD.
2. On the measuring equipment cabinet, select ”Straight-ahead driving" for the ”Incoming alignment
check", then ”Adjusting procedure" or the ”Outgoing alignment check". The following graphic appears
on the LCD monitor for ”Driving straight ahead".
3. Pressing the ”Forwards arrow" calls up the next measuring screen. What next appears on the LCD
display blocks are a designation of the measured value and a tolerance bar with measured value. If that
measured value is within tolerance, this is depicted with black numerals on a light background. If that
measured value lies outside the tolerance, it is then displayed in inverted fashion (i.e. light numerals on a
dark background).
4. Pressing the ”F" button briefly makes it possible to alternate between the designation of the measured
value and the nominal value with tolerance within the display block.
5. To scroll onwards through the measured values, press the ”Forward arrow", ”Backward arrow" and the
”Cancel" keys (red spot) . The function of this button is identical to that of the buttons/keys on the
graphics pad.
6. Even when opting for the ”Alignment check with non-selective access", the measured values can be
chosen in the same way as for the ”program-guided alignment check" process.
7. Using the ”Printer" button enables reports to be printed out during the alignment check. The remote
control buttons are only enabled during the measurement and setting process (not in response to
customer input, choice of vehicle, etc.).
- Measured values with nominal/actual comparison and tolerance bar (nominal values can be displayed by
pressing the ”F" key/button)
- Summary of measured values with the latest nominal / actual comparison
- Compensation for lateral runout on wheel rims
- With all other functions (e.g. customer input), the title image appears on the liquid crystal display
Note:
Whenever data transfer from the master key / remote control to the computer is interrupted, the
master key icon in the lower right-hand corner of the screen changes colour from green to red
and the image on the LCD display is depicted in inverted format, i.e. black becomes white and vice
versa. This changeover does not occur in the title image. Once visual connection is re-
established, the master key recommences work at the point in the program where the interruption
occurred. Continuous visual connection during the alignment check is therefore not necessary.
The ”Egg timer" icon on the LCD display indicates: ”Please wait".
The ”Battery" icon in the upper right-hand corner of the LCD display indicates that the battery
reserve has been reached.
Switching off the remote control / master key: Press and hold down the ”F" key for 5
seconds, then place in the charge bracket or plug in the charging cable. The title image then
reappears as the charge indicator light.
If the master key is placed in the charge bracket during the alignment check process, it must
when required be switched on using the ”ON" key.
11 Updating the software / nominal data
No more diskettes will be sent out to any BMW authorised workshops who in the past subscribed to ”BMW
KDS (Beissbarth / Bosch)". For reasons of cost, it is no longer possible to produce these diskettes in-house
on the ”DIS tester" or on the ”TIS/EPC server". The data are updated on the TIS-CD on a regular basis
11.1 Prerequisites
- BMW KDS (Beissbarth / Bosch)
- Program status (Beissbarth) TIS-CD: from CD 12/95
- Program status EPC: from 12/95
- Program status (Bosch) TIS-CD: from CD 08/97
- Program status DIS: from V6.0
- Diskettes, 3.5", 1,44 MB (Beissbarth 5 diskettes / Bosch 1 diskette)
1. Go into screen mask ”Administration"
2. Select KDS button
3. Select Beissbarth
4. After request, load ”diskette 1" and acknowledge with ”OK" (program diskette 1 of 2 is created, perform
labelling operation)
9. Perform software update and /or nominal data input on the KDS in the usual manner using the
manufactured diskettes.
3. Select Bosch
4. Write a name on ”Diskette 3.1", when prompted to do so, insert in the drive and confirm by pressing ”OK"
(2x) --> nominal values are then copied to the diskettes
5. Load nominal value diskette 3.1 in drive 3.1, load operating system diskette 3.0 in drive 3.0.
6. Boot device in the usual manner
Important!
When producing KDS diskettes, all data on the diskettes used are overwritten.
Note:
Whenever an error occurs, this is displayed and the program aborts. This process needs to be
restarted from the very beginning, which involves deleting all data from the diskette. Possibly use
a new diskette.
12.1 Copying
- Press the ”C" button and select the vehicle which is to be copied.
- In the special function section, select menu item ”Editing of nominal data". Set up a new vehicle record in
the familiar way. Now the data input screen displays the nominal values for the previously selected vehicle.
Re-enter the modified data and save the data record.
12.2 Create
- Press the ”C" button and, in the special function, select the ”Editing of nominal data" menu item. Set up a
new vehicle record in the familiar way. An empty data input screen now appears. Enter the data and save
the data record.
12.3 Edit
- Nominal data programmed in the factory cannot be deleted or changed. If these data are changed, a new
vehicle record with those amended nominal data needs to be set up. New vehicle records set up by the
user are designated as such in the selection menu with a ”+". These vehicles can be deleted by the user
by means of the screen button ”-" or can be amended using the ”< > ” button. These buttons only appear
on the screen if the vehicles were entered in the system by the user.
In the ”Special function" menu, the ”Customer-specific text" submenu can be called up. An input screen
appears on the display. A name and address must be added to this input screen and saved by pressing the
”S" screen button. The text entered is then imprinted in the header of the protocol / report.
13.2 Alignment options
- in the special functions (button ”S"), call up the ”Service" menu
- In the submenu ”alignment", select the ”Toe-in alignment" or the ”Toe-in adjustment" option. The toe-in
and camber alignment program guides the user step by step through the alignment process with the help
of text and images. At the end of the adjustment process, the deviation in measuring value from every
measuring sensor is displayed on the screen.
- These alignment values can be saved in the measuring pickup memory by pressing ”Save" or the program
can be quit by pressing the ”Red button" without saving (a checking function). The alignment values can be
printed out.
13.3 Turntable test
- In the ”Service" menu, call up the ”Turntable test" function. Rotate left and right-hand turntables and check
the display on the screen. Important: The measuring range is ± 306 degrees.
13.4 View and delete customer entries from the database
- In the special functions in the ”Database" menu, call up the ”Delete" menu option. The data input screen
then appears. Fill in the search boxes with the data to be deleted.
- Using the ”-" button, this data record can be deleted. It is now possible to use the touchscreen pen to
highlight and delete a new data record.
- The screen buttons ”Arrow up" and ”Arrow down" enable users to scroll through the entire database.
- To quit the Delete function, press the Cancel button (red spot).
Other internal program changes were made which only slightly alter the program run, but which do optimise the
alignment check in terms of comfort and speed. This is described in the following pages:
- Optimisation of compensation for lateral runout on wheel rims in relation to speed.
- Optimisation of impact routines: Marking can still be corrected within the gateway. The message
”Turntables not connected" no longer causes this routine to terminate. Measuring can continue after the
turntables have been plugged back in.
- Standardisation of screen colours with the colours on the panel.
- Extension of texts in some foreign languages.
- Elimination of program and cosmetic errors.
- Electronic water scales
- Discontinuation of wheelbase measurement
15. Faults
15.1 Tyre faults
Error Impact
1 Tracking, camber, toe difference angle and caster 1 Serious tyre squeak, even at relatively low
not correct speeds
2 Too much toe-in or too much positive camber 2 Tyres are worn longitudinally down one outside
edge
3 Too much negative camber 3 Tyre wear on inner edge

4 Worn front axle suspension points on FWD cars 4 Amplified noise /
Vehicle pulls away one-sidedly when accelerating
5 Incorrect toe adjustment 5 Radial adjustment of wheel settings /
tyre tread exhibits burr formation within the tread

pattern
6 Play in wheel suspension caused by mechanical 6 Washed out areas /

components (suspension, steering)
wobbling on front wheel
7 Insufficient inflation pressure in the tyre 7 Tyre wear along outer areas
Fault Cause Remedy
1. Toe deviation a) Vehicle not in normal position a) Correct ride height
b) Tie rod(s) bent b) Replace tie rod(s)
c) Ball joints on track rod(s) c) Replace tie rod(s)

misaligned
d) Rubber mount in control arm d) Replace control arms

faulty
2. Camber deviation: Camber is a) Rubber mount in control arm a) Replace control arms
defined by design and cannot faulty
be adjusted.
b) Control arm deformed b) Replace control arms
c) Spring strut deformed c) Replace spring strut
d) Guide joint worn d) Replace control arms
e) Spring deflection too great e) Replace coil spring, ride height

f) Front axle carrier deformed f) Replacing front axle support
g) Spring strut shock absorber g) Repair front end

mount misshapen
h) Distortion in floor assembly h) Repair body

(engine carrier)
3. Castor deviation: Caster is a) Rubber mount for a) Replace rubber mount

defined by design and cannot tension/traction strut defective
be adjusted
b) Tension/traction strut b) Replace tension/traction strut,

misshapen
c) Control arm deformed c) Replace control arms
d) Spring strut deformed d) Replace spring strut
e) Wheel house deformed e) Repair front end

(spring-strut mount)
f) Distortion in floor assembly f) Repair body

(engine carrier)
Prerequisite: camber and caster are

4. Toe angle difference correct
deviation
a) Tie rods not adjusted uniformly a) Adjust toe on left and right
sides to same value
Prerequisite: front wheels have

5. Wheel-offset deviation equal single toe to geometrical axis
a) Front axle carrier deformed a) Replacing front axle support
b) Engine carrier deformed b) Repair body

d) Tension/traction strut d) Replace tension/traction strut
misshapen
15.3 Rear axle defects
Fault Cause Remedy
1. Camber deviation a) Vehicle not in normal position, a) Correct ride height

spring deflection too great
b) Rubber mount on rear axle b) Replace rubber mount

carrier unserviceable
c) Rear axle carrier deformed c) Check rear-axle carrier,

replace if necessary
d) Control arm deformed d) Check/replace control arm
e) Traction strut misshapen e) Check traction strut, replace if

necessary
g) Swinging arm deformed g) Replace swinging arm
2. Rear-wheel position incorrect a) Rear axle carrier displaced a) Check rubber mounts on rear-
laterally axle carrier, replace if
necessary
b) Distortion in floor assembly b) Repair body
3. Toe deviation a) Vehicle not in normal position, a) Correct ride height

i.e. spring deflection too great
b) Rubber mounts in rear-axle b) Replace rubber mount

carrier faulty
d) Rubber mount and swinging d) Replace swinging arm

arm unserviceable
e) Rear axle carrier deformed e) Check rear-axle carrier,
f) Traction strut misshapen f) Check traction strut, replace if

necessary
Prerequisite: rear wheel total toe

4. Deviation from the geometric value must be correct.
axis
a) Distortion in floor assembly a) Repair body
Other notes on the topic of the ”kinematics diagnosis system" can be found in the BMW KDS (Beissbarth
/ Bosch) operating instructions.
None of the function and system descriptions are covered by an update service. Availability of parts and
scope for immediate ordering cannot be derived from this information. The specialist departments shall
be in touch with the markets at an appropriate time with further details.
360299(469)
Run-flat tyre and inflation pressure warning systems
All
General
Warning systems
BMW AG offers two different systems which warn the driver whenever pressure drops in one or more tyres.
System Designation Measuring procedure

RDC Tyre pressure control (RDC) Pressure/temperature in the tyre
TPW Tyre Pressure Warning Comparison of wheel speeds
Emergency running systems

In addition to the warning systems, two run-flat systems are used which prevent the pressure in any tyre from
dropping to zero:
Components of the run-flat system with self-supporting tyres:
RDW (standard equipment) Tyre Pressure Warning

RDC (from 03/2000 can be selected as an alternative Tyre pressure control (RDC)
cost option))
SST Self Supporting Tyre
Disc wheel EH2 Disc wheel with Extended Hump 2
Elements of the run-flat system with integrated support ring:
Support ring Note:

In future, only for heavy high-security
vehicles (E38/3)
RDC (optional) Tyre pressure control (RDC)
Disc wheel H2 Standard disc wheel with Hump 2
RDC tyre pressure control

RDC system overview
The RDC continuously monitors the inflation pressure and the temperature in the tyres while in motion and
when at a standstill. The data are transmitted by message from the wheel electronics, are received by the
aerials located in the wheel arch and then sent to the RDC control unit. There, the data are compared against
stored limit values.
After correction of the inflation pressure with the engine stationary and the ignition switched on, the Set button
should be pressed for long enough (approx. 6 seconds) for the instrument panel (high equipment instrument
panel) to light up yellow LEDs for ”inflation pressure set” or (basic version instrument panel).
Whenever readings drop below these limit values, the driver is warned in two stages by the instrument panel:
Tyre pressure loss Warning

Drop in tyre pressure from 0,2 to 0.4 bar Yellow LED on the basic version of the instrument
panel
or
Text: ”Check inflation pressure” on the high equipment
instrument panel
Gong: No
Drop of more than 0.4 bar in inflation pressure Red LED on the basic version of the instrument panel
or
Text: 'Puncture' on high equipment instrument panel
Gong: Yes
Benefits of the RDC
1. Safety - Early warning in response to rapid tyre pressure

loss
- Warning about tyre pressure losses due to natural
diffusion
2. Comfort - Consistent ride comfort

- Request for inflation pressure checks when required
3. Service life, economy - Minimisation of tyre wear

- Minimisation of fuel consumption
4. New developments - Facilitate use of run-flat tyres

- When using run-flat tyres spare wheel is dispensed
with (saving weight)
System structure of RDC
(1) RDC control unit (4) SET button
(2) Wheel electronics (4 pieces) (5) Display element

Wheel electronics for spare wheel (optional) (6) Anti-theft warning system
(3) Reception aerials (4 pieces) - Wiring harness
RDC control unit

With full diagnostic capability!
Task:
evaluates the following messages from the wheel electronics:
- Tyre pressure
- Tyre air temperature
- Identification number (ID) of the wheel electronics
- Remaining service life of battery, wheel electronics
When required, issues a notice or a warning.
Wheel electronics with valve

Elements:
- Pressure sensor
- Temperature sensor
- Transmitter
Country-specific frequencies
- Voltage supply
Service life, approx. 7 years.
cannot be replaced
Installation position of wheel electronics in the disc wheel

The wheel electronics (1) are bolted to the valve (2) on the disc wheel (3)
Identifying feature:
Metal tyre valves
Note:
Due to the differences in disc wheel geometries, different valve
also need to be used. The valves are colour-coded. The
correct encoding can be found in the spare parts catalogue.
Aerial
Wheel electronics are located in every wheel arch.
Task:
receives messages to be forwarded to the RDC control unit.
SET button
Installed on the dashboard to the right of the steering wheel.
(E46: In the centre console).
Symbol: tyre cross section
Task:
initialisation after a reset of the cold inflation pressure or after
changing tyres or wheel positions.
Display element on the instrument panel

Indicator lamp lights up yellow:
- Drop in tyre pressure of 0.2 to 0.4 bar
Indicator light lights up red:
- Drop in pressure greater than 0.4 bar
Run Flat Indicator RDW

System overview of the RDW
The RDW measures the wheel speeds of all four wheels using the wheel speed sensors on the ABS/ASC or
the ABS/DSC system. This compares the wheel circumferential velocities of the diagonally opposed wheels
and their average speed.
As a consequence of a possible tyre pressure loss, the dynamic diameter of the wheel changes, and this also
alters the wheel speed.
A tyre pressure loss of 30 ± 10 % can be identified on all wheels above 15 km/h and up to maximum speed.
Whenever this value is exceeded, the driver is warned by the instrument panel in the following manner:

Tyre pressure loss of 30 ± 10 % red LED
Text: 'Tyre puncture'
Gong: Yes
The vehicle can only be moved at a max. speed of

80 km/h (50 mph)!
Note:
A careful driving style with low levels of
longitudinal and lateral acceleration helps
to extend the service life of the faulty
tyre.
Advantages of the RDW

With two exceptions, the same advantages apply to the RDW as to the RDC.
Exceptions:
- No warning of a natural tyre pressure loss in the tyre.
- The inflation pressure continues to need checking regularly every 14 days.
System structure RDW
(1) Wheel speed sensors on the ABS/ASC or the (3) SET button
ABS/DSC system
ASC = Automatic Stability Control DSC = Dynamic

Stability Control (4) Display element
(2) RDW control unit - Wiring harness
RDW control unit

Task:
- Evaluates wheel speeds.

- Issues a warning when required.
SET button
Installed on dashboard to right side of steering wheel. Symbol:
Tyre cross section with warning triangle
Task:

- Drop in inflation pressure 30 ± 10 %
Run-flat systems
Introduction
Run-flat tyres can also be driven with care following complete loss of tyre pressure for a certain distance. A
distinction is made between two different systems which satisfy these requirements:
- Run-flat system with self-supporting tyre
- Run-flat system with integrated support ring
Layout of the run-flat systems
Run-flat system with self-supporting tyre
The side walls on self-supporting tyres are reinforced. The tyres in conjunction with a special disc wheel can
also be driven carefully over a defined distance following a complete loss of tyre pressure.
Mobility remains assured up to a maximum speed of 80 km/h (50 mph) for the following distances, subject to a
careful and appropriate driving style:
Vehicle unladen max. 500 km

Roadster unladen less then 250 km
Vehicle fully laden max. 50 km
These self-supporting tyres require continuous monitoring of inflation pressure to warn the driver of any tyre
pressure loss while driving the vehicle. This is why these tyres are only offered in conjunction with the RDW
warning system, and from 03/2000 with RDC.
To prevent self-supporting tyres from jumping off the disc wheels when they suffer complete tyre pressure
loss, redesigned wheels with modified disc wheel humps but the same tyre seat (=standard disc wheel) need
to be fitted.
However, the new wheels are also suitable for normal tyres of any size.
Comparison between standard tyres and self-supporting tyres
Standard tyres depressurised / deflated
Self-supporting tyres depressurised / deflated

Devulcanised reinforcement (1) made of temperature-resistant
rubber compound
Disc wheels
H2-disc wheel (standard disc wheel) for run-flat system with integrated support ring
(1) Hump 2 on the standard disc wheel
EH2-disc wheel for run-flat system with self-supporting tyre
(1) Extended hump 2 on the disc wheel
(2) Wheel drop centre relocated a few millimetre inwards (pre-
centring on the outer side)
Note:
The new EH2-disc wheels (extended hump 2 inner and outer) will be used more frequently in
future by BMW because, also in conjunction with normal tyres, they make it much less likely for
the much feared loss of a tyre in response to tyre pressure loss, i.e. they move that tyre loss
point down to much lower inflation pressures.
Example: From at present 1.1 bar to 0.6 bar (X5- or Landrover disc wheel)
Run-flat system with integrated support ring:
(in future, preferably on heavy high-security vehicles)
The support ring is made of high-strength flexible plastic and is fitted into the tyre on a standard disc wheel. It is
only possible to dismantle the support ring using specialist tools approved by BMW, and cannot take place
until the tyre has been complete destroyed.
Run-flat systems with integrated support ring are specifically chosen for use in heavy-duty high-security
vehicles. Even in the event of total loss of tyre pressure, they allow these vehicles to leave a potential danger
area without having to reduce speed (escape situation).
There is the option of monitoring the inflation pressure with an RDC. The RDC is installed by pressing in the
support ring before installation.
Fitting a wheel with integrated support ring
Run-flat system with integrated support ring

(1) Tyre
(2) Support ring
Installation location for the RDC wheel electronics
(1) Wheel electronics
(2) Support ring
Other notes on the subject of ”inflation pressure warning systems and tyres with run-flat properties” - see
operating instructions.
For orders, a BMW Parts Department information bulletin is being produced.
23 01 03 (002)
Sequential manual transmission (SMG), based on GS6-37BZ
E46
Introduction
The idea of a Sequential Manual Gearbox (SMG) originates in motor racing and has now been adapted for
volume production road vehicles.
Specifically, SMG means that in contrast to conventional manual gearboxes, the clutch control and gear
changes are automated. An electrohydraulic control system handles the functions that are otherwise
performed by the driver shifting with the clutch pedal, gear lever and accelerator pedal.
The Sequential Manual Gearbox SMG makes possible
Sequential manual gear change = manual mode
The gears are engaged sequentially by pressing the tip switch ”+/-”. Rapid repeated action of this 'tip
switch' enables individual gear ratios to be skipped.
Gear changes (shifts) are performed
using the shift lever in the centre console
using 2 shift paddles on the steering wheel.
The gears can be engaged manually at any vehicle speed and/or with the accelerator pedal in any
desired position. The shift pulse is transmitted electrically to the SMG control unit. With this gearshift
method (”shift‐by‐wire”) there are no mechanical linkages between the gear lever or shift paddles and the
transmission.
Automatic function = cruise mode
In automatic function, the gear shifts are controlled and adapted automatically in accordance with
characteristic curves and the driving situation. [System overview ...]
To differentiate from the SSG sequential transmission (C-SMG) used until now in the E46, based on the 5-
speed manual gearbox (C transmission), the new SMRG introduces the following changes:
The SMG GS6S37BZ (H-SMG) based on the 6-speed manual gearbox GS6-37BZ (H transmission).
The attachment positions of the hydraulic components and the sensors on the transmission housing
have changed.
For the high pressure lines on the hydraulic unit, flexible lines with snap fasteners are used.
The electromechanical reversing light switch has been dropped and replaced by a relay in the electronics
box.
The forced upshift and the kickdown downshift are dispensed with in manual mode. Exception: When
using the launch control (race start function), the forced upshift is retained to support the driver.
The FDC driving dynamics control system can also be engaged in automatic function (SPORT button).
The SMGs offer the following major advantages when compared to conventional manual gearboxes:
No longer any need for the clutch pedal because the engagement and disengagement process runs
automatically
Shift options - choice of 3 shift modes:
Sequential, manual shifts using gearshift lever and shift paddles
Driving dynamics control (FDC) using SPORT button: A more sporty driving style through
intervention in the steering, engine and electronic transmission control (in manual mode and in
Cruise mode = automatic mode)
Automatic function = cruise mode
Short and precise gear shifts, no shift errors possible (gear changes in up to 0.15 seconds)
Active safety and comfort: due to the shift paddles on the steering wheel, hands can remain on the
steering wheel when changing gear.
Launch date: The SMG will be offered as optional equipment (SA 206).
Model Engine Planned introduction date

E46 M54B25 M54B30 03/03 worldwide, except for USA, CAN, OFF

The SMG system consists of the following components:
Gearshift lever with gearshift bracket and gearshift lever cover
The gearshift lever makes it possible to change gear sequentially using 'tip' action. The gearshift lever
has 6 positions: 3 spring-loaded engaged positions for neutral ”N”, reverse gear ”R” and manual mode
(symbol ”-” between Neutral and Cruise mode) as well as 3 non-engaged positions which are only 'tipped'
(”+”, ”-”, ”C” (Cruise mode = automatic function). To detect the gear lever positions, the gearshift bracket is
equipped with 7 Hall effect sensors. The shift lever interlock (Shiftlock) is also installed on the gearshift
bracket.
The gearshift lever cover houses the illuminated gearshift lever position indicator and the SPORT button
for engaging the Driving Dynamics Control (DDC). [more ...]
Steering wheel with rocker switches
The steering wheel with shift paddle enables manual gear changes to be made without taking your hands
off the steering wheel. By pulling one or both shift paddles, an upshift takes place. By pressing them, the
transmission performs a downshift. [more ...]
SPORT button for dynamic driving control FDC
Dynamic Driving Control (FDC) is activated with the SPORT button: Gearshift times are shortened and the
shift characteristics are made more sporty. The engine responds more swiftly to changes in the position
of the accelerator pedal.
When the engine starts, the Dynamic Driving Control (DDC) function is always disabled. [more ...]
Hydraulic unit with sensors
With the help of the hydraulic unit and the sensors, the clutch process and the gear changes are
performed automatically. [more ...]
Shift/selection angle actuator
The shift/selection angle actuator moves the gearshift shaft along its axis and rotates the gearshift
shaft during gate changes. [more ...]
Shift travel sensor and selector angle sensor
The current transmission position is identified by the shift travel sensor and selector angle sensor:
The shift travel sensor records the forward and backward movement of the gearshift shaft in each of
its shift gates.
The selector angle sensor detects the rotational movement of the gearshift shaft and therefore also
the change in shift gate. [more ...]
Pressure accumulator
The pressure accumulator is installed on the lower left of the gearbox and ensures that the oil
pressure is always sufficient for the gear shifts. A piston subdivides the pressure accumulator into
2 chambers. One chamber is filled with approx. 27 bar nitrogen at -25°C. The second chamber takes
in the oil emerging from the hydraulic pump. It has a storage volume of approx. 285 cm3.
Pressure sensor
The pressure sensor is directly installed on the valve block and reports prevailing oil pressure to the
SMG control unit. The hydraulic pump is switched on or off as required.
Clutch actuator with clutch release travel sensor
The clutch actuator performs clutch engagement and disengagement. The release travel of the
clutch is detected by the clutch release travel sensor. [more ...]
Hydraulic pump
The hydraulic pump with electric motor develops a system pressure of up to 55 bar and is activated
by the SMG control unit.
Sensor for transmission input speed
The sensor records the transmission input speed and compares it to the engine speed. This
comparison enables the SMG control unit, to decide the level of closing speed at which power flow
between engine and transmission can be established via the clutch.
Expansion tank
The expansion tank ensures that there is always sufficient hydraulic fluid for the system. Moreover,
oil in the expansion tank can expand. To check the oil-level, there is a maximum and a minimum mark
on the expansion tank. For pre-filtering the oil a filter is integrated in the expansion tank.
Valve block
The valve block houses the solenoid valves, the pressure sensor, the pressure accumulator, a
non-return valve and a fine filter.
Solenoid valves
The valve block contains a total of 4 solenoid valves. 3 solenoid valves control the clutch actuator
and the shift actuator for shift movement.
1 solenoid valve controls the selector angle brake (S-Cam = sleeve with s-shaped contour) and the
shift/selector angle actuator used to perform gate changes. The solenoid valve also acts as a
pressure relief valve for the hydraulic system.
The solenoid valves are only energise during clutch operation and gear changes.
SMG control unit
The SMG control unit is the one familiar from the E46, i.e. the GS30. The SMG control unit calculates the
activation signals for the solenoid valves for clutch operations and gear changes from these sensor
signals. In addition, the SMG control unit provides information to various control units, e.g. for adaptation
of engine speed, for program display and for display of gear lever position. [more ...]
Relay for the reversing light
The signal for the selector lever position of reverse gear is directed to the SMS control unit by the shift
travel sensor and the selector angle sensor. The SMG control unit generates the signal for the relay. The
relay for the reversing light is located in the end cover of the electronics box.
Transmission
The SMG is based on the 6-speed manual gearbox GS6-37BZ. The gearbox housing has been modified
and houses the hydraulic unit with the actuators for clutch operations and gear changes as well as
additional sensors. The gear detent and selector detent on the gearshift shaft have been adapted. The
transmission layout and the clutch remain unchanged.
Instrument panel display
The selected drive positions and driving programs and the symbol for operate in the emergency program
are depicted in 3 segments on the instrument panel. [more ...]
Additional measured variables of the following components:
Brake light switch
The signal from the brake light switch enters the SMG control unit in the same way. For safety purposes,
the signal from the brake light switch is transmitted by the DME control unit (Digital Engine Electronics) via
the PT-CAN (drive train CAN).
The signal of the brake light switch is used for the following operations:
To unlock the shift lever interlock (Shiftlock)
For brake detection
To configure a gear during engine standstill
Starter lock and electronic immobiliser EWS
The electronic immobiliser only enables the starter motor if the SMG control unit issues the release
signal. Via the input on terminal 50, the SMG control unit identifies a wish to start the engine. The following
conditions must be met for a start enable to take place:
Gear lever position N must be engaged ("N" must appear on the display on the instrument panel).
SMG control unit releases engine start, and the clutch opens.
System functions
The SMG comprises the following functions:
Engine start
Gear shift
Driving in Cruise mode ”C” (automatic function)
Launch control (racing start function)
See-sawing free, e.g. out of a snow drift
Vehicle at a standstill
Gear lever position in Neutral (N) and ignition OFF
Fault display, SMG warning light and emergency program
Engine start
To start the engine, gearshift lever and transmission must be in ”N” (Neutral). To ensure when the engine
starts that there is enough system pressure to open the clutch, the SMG control unit is woken up by the
basic module when the vehicle doors are unlocked remotely. Storage pressure is calculated. If storage
pressure is too low, the hydraulic pump is activated once only. Once the system pressure has been
reached, the hydraulic pump is switched off again by the SMG control unit. The "wake-up signal" activates
the gear lever position display in the centre console. If after approx. 15 minutes, terminal 15 is not enabled,
then the display of gear lever position is switched off again.
Gear shift
If in manual mode or in Cruise mode a gear shift is activated, the SMG control unit then activates the
corresponding sequence of solenoid valves in the valve block. The pressurised hydraulic fluid flows into the
clutch actuator and actuates the clutch. At the same time, the SMG control unit transmits information that a
gear shift has been initiated and the request to reduce the engine torque to the DME control unit. In the
next step, the shift/selector angle actuator is activated. The shift/selector angle actuator carries out the
gear shift by simultaneously moving the gearshift shaft backwards and forwards and also rotating the
gearshift shaft. This gear shift is supported when required by raising the engine speed (dipping the throttle).
Once the gear has been engaged, the clutch closes automatically. The SMG control unit receives
information about the precise clutch position from the clutch release travel sensor. After the shift operation,
the current to the solenoid valve is switched off. The entire gear shift runs as a function of pedal sensor
position, driving speed, engine speed, transmission speed and other factors (e.g. engine oil temperature).
Just before the vehicle comes to a standstill, the SMG switches to 1st gear and opens the clutch. The
power transmission between engine and transmission is interrupted.
Gearshifts that would result in an excessively high or low engine speed are suppressed.
Driving in Cruise mode ”C” (automatic function)
Constant-speed driving
Continuous changes in pedal sensor position (depressing then releasing the accelerator) are
recorded in the SMG control unit. The control unit prevents the continuous change between
neighbouring gears that this causes (back and forth/ [known as "hunting"], e.g. on a journey on the
motorway at continuously changing vehicle speeds).
Upshift suppression
The SMG control unit uses the pedal sensor on the accelerator pedal to detect fast closure of the
throttle and activates the upshift suppression function. This prevents undesired / accidental upshifts
(e.g. prior to braking) and the engine braking effect is retained.
Hill ascent
The SMG control unit detects from data provided by the wheel speed sensors and the accelerator
pedal value that the vehicle is driving uphill and prevents (e.g. by retaining the same engine speed but
reducing pressure on the accelerator pedal) accidental upshifts and troublesome pendulum shifts.
Driving downhill
Via signals from the throttle valve potentiometer (load signal), from the wheel speed sensors (driving
speed) and from the brake light switch (braking mode), the SMG control unit detects downhill driving.
To retain and increase engine braking effect, the SMG control unit shifts down into the next lowest gear
when driving speed increases.
Braking deceleration and automatic downshifting
The SMG control unit uses the brake light switch, the wheel speed sensors and the accelerator pedal
value to detect braking deceleration. To maintain the engine braking effect, the SMG control unit shifts
down according to the driving speed. Here, a number of gears can be skipped. For renewed
acceleration, the right gear is selected automatically.
Manual intervention by the drive in the automatic function
If the drive actuates the gearshift lever or the shift paddles while in automatic function (Drive), the
system automatically shifts into Manual mode. The automatic function then needs to be chosen again
by the driver.
Launch control (racing start function)

Prerequisites for the launch control:
Roadway with good surface grip
Dynamic Stability Control DSC shut down (press and hold down the DSC button for more than 3
seconds)
SPORT button pressed
The launch control makes it possible for optimum acceleration at motor racing standards to be obtained
straight from vehicle standstill. Normally, clutch engagement takes place at approx. 1300 rpm. With the
launch control, speed increases to approx. 4000 rpm before the SMG system closes the clutch. For this, all
the driver has to do is to depress the accelerator pedal quickly and completed (kickdown function). The
forced upshift in Manual mode (only with the race start function) ensures that the engine does not reach
any critical speeds. The race start function is disabled by reduction of the kickdown function via the position
of the accelerator pedal, by a manual shift request, by switching off the driving dynamics control (DDC)
function using the SPORT button or by activation of the DSC function.
See-sawing free, e.g. out of a snow drift

To see-saw free, e.g. out of a snow drift, move the gearshift lever rapidly from 1st gear position to ”R”
(reverse) or vice versa. The gear shift must take place within 0.8 seconds otherwise the shift lever interlock
(Shiftlock) is enabled.
Vehicle at a standstill
If the SMG control unit identifies that the vehicle is stationary from the pedal sensor on the accelerator
pedal, the wheel speeds and the engine speed, regardless of driving program (Manual mode or Cruise
mode), the clutch is opened and 1st gear is engaged.
With the engine running, whenever the driver's door is open, attention is drawn to any engaged drive
position (warning signal 9 times in succession). Symbol N flashes (9 times) on the instrument panel. If
neither pedals, shift paddles nor the gearshift lever is actuated, the gear is disengaged automatically about
2 seconds later.
Gear lever position in Neutral (N) and ignition OFF

If the gearshift lever is in Neutral position and the ignition is switched off, the 'N' symbol flashes in the
transmission program display on the instrument panel. The standard acoustic sensor in the instrument
panel issues a warning signal for approx. 9 seconds. The acoustic sensor is activated by the SMG control
unit.
Fault display, SMG warning light and emergency program

The SMG warning light lights up and the warning signal sounds
Whenever the SMG warning light lights up and a warning signal is issued, the driver is made aware of a
fault in the SMG (e.g. failure of a sensor). Using substitute values, the fault is corrected in the SMG
control electronics. The fault can have an impact on shift and driving quality.
Driving program ”C” is displayed, the SMG warning lamp lights up and a warning signal sounds
The SMG is in its emergency program, i.e. restricted shift and driving quality, upshifts possible up to
max. 3rd. gear, and max. driving speed is limited to approx. 80 km/h (50 mph).
Transmission fault ”F” is displayed, SMG warning lamp lights up and a warning signal sounds
The driver's attention is drawn to the presence of a serious gearshift lever/transmission fault. The
vehicle is no longer operational after a vehicle standstill.

The following notes for Service can be issued at this time:
Diagnosis: ---
Car & Key Memory ---
National-market version
US version
The SPORT button (element of SA 224 Driving Dynamics Control) is only available with optional
equipment M-sports suspension (SA 704) or SMG (SA 206).
Subject to change.
36 04 99 (502)
Storage of wheels and tyres
All
Tyre / wheel storage, general
The storage of customer wheels is a service that almost goes without saying. For this reason, BMW Service
Technology should have a standard storage concept to prevent damage caused by incorrect storage.
Under the influence of sunlight, heat, humidity, moving air and ozone, the rubber in the tyre ages and loses
part of its strength and elasticity. For this reason, tyres must never be stored outdoors. If there is no
alternative to storing tyres outside for an extended period, the wheels/tyres must be clean and dry, and
covered with a waterproof material. In all cases, wheels / tyres must be protected from rain, snow and sunlight
but, due to the risk of corrosion, must not be stored in tyre bags. On the subject of tyre and wheel protection,
also refer to SI 36 01 88 (864).
Wheels / tyres with tyre pressure control (RDC) must not be treated using high pressure cleaners. General
information about the RDC - see SI 36 02 98 (377).
Requirements for the storage room
For storage in a sealed room, the following requirements apply:
cool 15...25 ° C / protect from heat sources or maintain a minimum

distance of1 metre from heat sources
dry Avoid water and condensationDo not bring into contact with
mineral-based greases
dark Protect against direct sunlight and artificial light with a high UV
content
moderate ventilation Avoid the ingress of oxygen and ozone
The storage room must therefore be cool and dry. There is no need for heating during the cold months. In
summer, keep doors and windows closed to prevent the ingress of draughts. Windows can also be painted
with protective paint.
The storage room must not contain any operating electrical machinery, welding equipment, switchgear etc.
because electrical sparks generate ozone which has an adverse impact on the surface of tyres (ozone
cracks).
Tyres should not be coated with oil, petrol or other mineral-based greases; these dissolve rubber and the tyre
becomes porous..
Tyre- / wheel preparation
1. Mark position of wheel on vehicle when removing wheel.
2. If possible, leave tyres on their wheels (wheel with tyre).
3. Correct inflation pressure and check every 2 months.
4. Ensure they are stored far enough off the ground. Never store wheels / tyres on the ground.
5. Fill in the stock reception slips. These must include the following details::
Type and size of tyre
Condition and tread depth
Customer address
Date and signature of customer
Requirements on the tyre / wheel mounting
A. Tyre fitted to wheel
Do not put down, ...

Note:
If there is no alternative to storing the wheels upright on the ground, increase their inflation
pressure to 3.5 bar.
... suspend instead, ...
... or stack them.

Note:
Never store them on the ground.
Use wooden pallets or similar supports.
B. Unfitted tyres
Do not stack, ...
... do not suspend, ...

... but instead put it down flat and turn it every 4 weeks.
Note:
Use standard shelving.
32 01 99 (503)
Table of contents
1. Foreword
1.1 Objective
1.3 Technical data
2.1 Front Axle
2.2 Rear Axle
3.2 Computer
3.3 Graphics pad
3.5 Remote display
3.9 Sensor tips
4. Work bay
4.1 Environment
5.2 Camber
5.3 Toe
5.4 Castor
6. Wheel suspension
6.1 Rigid axle
8. Special features
8.2 System setting
11.1 Preconditions
12.1 Copying
12.2 Creating
13.3 Editing
13.3 Turntable test
15. Error
15.1 Tyre fault

1 Preface
1.1 Objective
that arise.
Service.
may be used.
1.3 Technical data
3. Wheel sizes - 12"...20"

50 mm, weight 18 kg

65 mm, weight 17 kg


1 Brake tensioner

2.1 Front axle
2.2 Rear axle
- Camber
- Axial offset
3.2 Computer
PC sector.
3.3 Graphics pad


batteries).
3.5 Remote display

display facility:


3.9 Sensor probes

number: BS 90 19 11).
on rims.

4. Workbay
4.1 Environment
facility

ramps).

Note:
Important!
5.2 Camber
5.3 Toe-in

5.4 After-run


6. Wheel suspension
6.1 Rigid axle


forces.
axle).

range
Total toe-in (FA + RA) ± 2' ± 2° ± 18°
Camber (FA + RA) ± 1' ± 3° ± 10°
Castor ± 4' ± 18° ± 22°
Note:
8. Special features
8.2 System settings
Bosch Beissbarth
display
Monitor 20" 17"
Important!
dark background).
graphics pad.
Note:
11.1 Prerequisites
3. Select Bosch
Important!
Note:
a new diskette.
12.1 Copying
12.2 Create
the data record.
12.3 Edit
printed out.
13.3 Turntable test
15. Faults
15.1 Tyre faults
Error Impact
not correct speeds
edge


pattern

Fault Cause Remedy

misaligned

faulty
be adjusted.


mount misshapen

(engine carrier)

be adjusted

misshapen


(engine carrier)

deviation
sides to same value


misshapen
Fault Cause Remedy




necessary
necessary


carrier faulty

arm unserviceable

necessary

axis
32 01 99 (503)
Table of contents
1. Foreword
1.1 Objective
1.3 Technical data
2.1 Front Axle
2.2 Rear Axle
3.2 Computer
3.3 Graphics pad
3.5 Remote display
3.9 Sensor tips
4. Work bay
4.1 Environment
5.2 Camber
5.3 Toe
5.4 Castor
6. Wheel suspension
6.1 Rigid axle
8. Special features
8.2 System setting
11.1 Preconditions
12.1 Copying
12.2 Creating
13.3 Editing
13.3 Turntable test
15. Error
15.1 Tyre fault

1 Preface
1.1 Objective
that arise.
Service.
may be used.
1.3 Technical data
3. Wheel sizes - 12"...20"

50 mm, weight 18 kg

65 mm, weight 17 kg


1 Brake tensioner

2.1 Front axle
2.2 Rear axle
- Camber
- Axial offset
3.2 Computer
PC sector.
3.3 Graphics pad


batteries).
3.5 Remote display

display facility:


3.9 Sensor probes

number: BS 90 19 11).
on rims.

4. Workbay
4.1 Environment
facility

ramps).

Note:
Important!
5.2 Camber
5.3 Toe-in

5.4 After-run


6. Wheel suspension
6.1 Rigid axle


forces.
axle).

range
Total toe-in (FA + RA) ± 2' ± 2° ± 18°
Camber (FA + RA) ± 1' ± 3° ± 10°
Castor ± 4' ± 18° ± 22°
Note:
8. Special features
8.2 System settings
Bosch Beissbarth
display
Monitor 20" 17"
Important!
dark background).
graphics pad.
Note:
11.1 Prerequisites
3. Select Bosch
Important!
Note:
a new diskette.
12.1 Copying
12.2 Create
the data record.
12.3 Edit
printed out.
13.3 Turntable test
15. Faults
15.1 Tyre faults
Error Impact
not correct speeds
edge


pattern

Fault Cause Remedy

misaligned

faulty
be adjusted.


mount misshapen

(engine carrier)

be adjusted

misshapen


(engine carrier)

deviation
sides to same value


misshapen
Fault Cause Remedy




necessary
necessary


carrier faulty

arm unserviceable

necessary

axis
32 01 99 (503)
Table of contents
1. Foreword
1.1 Objective
1.3 Technical data
2.1 Front Axle
2.2 Rear Axle
3.2 Computer
3.3 Graphics pad
3.5 Remote display
3.9 Sensor tips
4. Work bay
4.1 Environment
5.2 Camber
5.3 Toe
5.4 Castor
6. Wheel suspension
6.1 Rigid axle
8. Special features
8.2 System setting
11.1 Preconditions
12.1 Copying
12.2 Creating
13.3 Editing
13.3 Turntable test
15. Error
15.1 Tyre fault

1 Preface
1.1 Objective
that arise.
Service.
may be used.
1.3 Technical data
3. Wheel sizes - 12"...20"

50 mm, weight 18 kg

65 mm, weight 17 kg


1 Brake tensioner

2.1 Front axle
2.2 Rear axle
- Camber
- Axial offset
3.2 Computer
PC sector.
3.3 Graphics pad


batteries).
3.5 Remote display

display facility:


3.9 Sensor probes

number: BS 90 19 11).
on rims.

4. Workbay
4.1 Environment
facility

ramps).

Note:
Important!
5.2 Camber
5.3 Toe-in

5.4 After-run


6. Wheel suspension
6.1 Rigid axle


forces.
axle).

range
Total toe-in (FA + RA) ± 2' ± 2° ± 18°
Camber (FA + RA) ± 1' ± 3° ± 10°
Castor ± 4' ± 18° ± 22°
Note:
8. Special features
8.2 System settings
Bosch Beissbarth
display
Monitor 20" 17"
Important!
dark background).
graphics pad.
Note:
11.1 Prerequisites
3. Select Bosch
Important!
Note:
a new diskette.
12.1 Copying
12.2 Create
the data record.
12.3 Edit
printed out.
13.3 Turntable test
15. Faults
15.1 Tyre faults
Error Impact
not correct speeds
edge


pattern

Fault Cause Remedy

misaligned

faulty
be adjusted.


mount misshapen

(engine carrier)

be adjusted

misshapen


(engine carrier)

deviation
sides to same value


misshapen
Fault Cause Remedy




necessary
necessary


carrier faulty

arm unserviceable

necessary

axis
36 01 04 (078)
Run Flat Indicator
All models
Introduction
The Run Flat Indicator (RPA) monitors the tyre pressure throughout the journey.
The entire vehicle weight is carried by the tyre pressure in the tyres. If the tyre pressure in one of the tyres
should drop, the tyre will gradually "cave in". The resulting flexing means that the faulty tyre will quickly receive
additional damage during driving. The tyre could burst.
Some 80% of all punctures are caused by small holes (e.g. caused by nails). The holes result in a gradual loss
of tyre pressure in the affected tyre. Many "tyre blowouts" can be traced back to preliminary damage caused
by a gradual loss of tyre pressure.
A gradual loss of tyre pressure in one tyre may remain unnoticed for a long time. The lack of tyre pressure only
makes itself clearly felt when driving when the tyre is almost completely depressurised.
As tyre pressure drops, the radius of the wheel and with it the tyre rolling circumference will also decrease. The
upshot is that the wheel speed of the affected tyre is increased. The RPA records the wheel speeds using the
wheel-speed sensors of the Dynamic Stability Control (DSC). The Run Flat Indicator compares the speeds of
the individual wheels and computes an average speed. In this way the RPA is able to detect a loss of tyre
pressure.
The RPA detects a drop in pressure below about 30 % ± 10 % of the initial value. The RPA indicator and warning
light indicates a drop in tyre pressure. The RPA will indicate this after just a short distance, as a rule after a few
minutes, from a certain minimum speed (e.g. 25 km/h) up to the permissible top speed.
> Different control units for the Run Flat Indicator [System overview ...]
> E46 All-wheel drive [System overview ...]
> E46, E53, E83, E85, E86 [System overview ...]
> E60, E61, E63, E64 [System overview...]
> E65, E66 [System overview...]
> E70 [System overview ...]
> E87, E90, E91, E92, E93 [System overview ...]
> R56 [System overview ...]
Despite coming from different manufacturers the systems hardly differ from one model series to the next in the
way they appear to the driver (initialisation, Run Flat Indicator telltale and warning lamp, characteristics,
diagnosis).
Caution! Responsibility resides with the driver at all times
Check tyre pressures regularly, at least twice a month and before embarking on lengthy journeys.
During initialisation, the set tyre pressure is taken as the initial value for the current set of tyres.
If all 4 tyres lose tyre pressure at the same rate, the wheel speeds will also change at the same
rate. The Run Flat Indicator is unable to detect a uniform drop in pressure in all tyres (e.g. due to
diffusion = natural loss of air from all 4 tyres)
Caution! Correct function of the Run Flat Indicator is not guaranteed when the compact spare wheel is
fitted.
As the compact spare wheel has a much smaller diameter, the correct operation of the Run Flat
Indicator can no longer be guaranteed.
The SMG system comprises the following key components:
4 wheel speed sensors
The wheel speed sensors of the Dynamic Stability Control (DSC) measure the wheel speeds of the
individual wheels.
Run Flat Indicator button
> E46, E53, E83, E85, E86
The Run Flat Indicator button is only needed for initialising the RPA. (Run Flat Indicator initialisation means
"teaching the system the tyre pressures").
CID: Central information display
Vehicles that are equipped with CID are initialised using the CID.
On-board computer button and rocker button on the turn signal/high beam switch
> E87, E90, E91, E92, E93, R56
Initialisation is performed on the liquid crystal display, using the on-board computer button and the rocker
switch on the turn signal/high beam switch. The on-board computer functions are selected with the rocker
switch.
The R56 does not have a rocker switch. The on-board computer functions are selected with the on-board
computer button.
The Run Flat Indicator software is in the following control units, depending on model series:
Run Flat Indicator control unit
E46 all-wheel drive vehicles
The E46 all-wheel drive vehicle has a separate Run Flat Indicator control unit. The 4 wheel speed sensors
measure the wheel speeds. The DSC control unit sends the signals through 4 direct lines to the Run Flat
Indicator control unit.
or
DSC control unit with additional software for flat tyre monitor
> R56
The ABS control unit is standard equipment on the R56. Run Flat Indicator is integrated into the DSC
control unit by means of additional software.
or
> R56
ASC+T is optional equipment on the R56 (ASC+T: Automatic Stability Control + Traction (ASC+T)). Run
Flat Indicator is integrated into the ASC+T control unit by means of additional software.
or
> E46, E53, E60, E61, E63, E64, E70, E83, E85, E86, E87, E90, E91, E92, E93
> R56: Optional equipment
With the DSC Mk60 and the DSC 8, the Run Flat Indicator is integrated into the DSC control unit using
additional software (the E70 is equipped with DSC 8 Premium).
or
CIM: Chassis integration module
> E65, E66
The CIM controls:
Servotronic
Steering column adjustment
Run Flat Indicator (RPA)
The following control units are involved in the Run Flat Indicator system (in alphabetical order):
CAS: Car Access System
> E60, E61, E63, E64, E65, E66, E70, E87, E90, E91, E92, E93, R56
The CAS control unit provides input signals relating to terminal status (e.g. terminal 15 ON).
GM: Basic module
> E46, E53, E83, E85, E86
The basic module provides input signals relating to terminal status (e.g. terminal 15 ON).
JBE: Junction Box Electronics
> E70, E87, E90, E91, E92, E93, R56
The JBE is the data interface (= gateway) between the K‐CAN and the PT‐CAN. (K‐CAN stands for "Body
Controller Area Network"; PT‐CAN stands for "Powertrain Controller Area Network")
The junction box consists of the junction box electronics and the power distribution box.
KGM: Body gateway module
> E60, E61, E63, E64 from 09/2005
The body gateway module (KGM) replaces the safety and gateway module (SGM).
The KGM forms the data interface (= gateway) between the K‐CAN and the PT‐CAN.
M‐ASK or CHAMP or CCC: Multi‐audio system controller or multimedia platform or Car
Communication Computer
M‐ASK or CCC or CHAMP (multimedia platform: CHAMP; Central Head Unit and Multimedia Platform)
issues an acoustic warning through the speakers if the tyre pressure should drop.
(On vehicles without M‐ASK or CCC or CHAMP, the instrument panel will emit the warning.)
SGM: Safety and gateway module
> E60, E61, E63, E64 up to 09/2005
> E65, E66 from 03/2004
The SGM is the data interface (= gateway) between the K‐CAN, byteflight and the PT‐CAN.
SZL: Steering column switch cluster
> E87, E90, E91, E92, E93, R56
The signals from the on-board computer button and from the rocker switch are recorded and processed in
the SZL. The data is transmitted to the instrument panel (on-board computer).
ZGM: Central gateway module
> E65, E66 up to 03/2004
The ZGM forms the data interface (= gateway) between the K‐CAN and the PT‐CAN.
KOMBI and CID: Instrument panel and Central Information Display
A fault in the Run Flat Indicator or drop in tyre pressure will be indicated by the Run Flat Indicator telltale
and warning lamp in instrument panel.
At the same time, the symbol will light up in the liquid crystal display.
Fault statuses registered by the Run Flat Indicator are indicated as follows by the Run Flat Indicator
telltale and warning lamp (for deviations, please refer to national-market version):
The Run Flat Indicator telltale and warning lamp lights up:
Red (with acoustic signal):
The tyre pressure loss is more than approx. 30 % ± 10 %. Driving safety is no longer
guaranteed.
Yellow:
Run Flat Indicator failed
Information about the check control message can be called up in the CID (CID is fitted depending on the
vehicle equipment).
[more ...]
System functions
The Run Flat Indicator (RPA) comprises the following functions:
Self-test
Initialisation
Detects drop in tyre pressure
Visual and acoustic warning
Actively relieve faulty wheel (only E70)
Self-test
The Run Flat Indicator performs a self-test when terminal 15 is switched ON. A fault in the Run Flat Indicator
is indicated by the Run Flat Indicator telltale and warning lamp and by a symbol in the liquid crystal display.
Initialisation
Initialisation is started manually (e.g. by pressing the Run Flat Indicator button). Once it has been started,
initialisation will continue through to complete calibration. This process may be interrupted any number of
times.
It is important that the vehicle is driven away immediately after initialisation is started. The system will not
start calibration until the vehicle is driven away. Even a terminal change will not change this.
In principle, calibration is only possible while the vehicle is being driven (driving speeds above 25 km/h).
Initialisation will run as a fully automatic calibration sequence (after the journey has started),. In other words,
the circumference of individual tyres are recorded and evaluated.
To allow a drop in tyre pressure to be detected, the system considers different speed ranges and driving
situations. Taking account of the driving situation means that the system has to be primed for each speed
range individually.
From 09/2004 (starting with E87), these speed ranges and driving situations have been combined into 3
calibration ranges. This means greater clarity for output via the BMW diagnosis systems Group Tester One
(GT1) and DISplus.
The initialisation phase lasts approx. 5 to 15 minutes for the individual speed ranges. The end of the
initialisation phase is not indicated.
A visual and acoustic warning can only be emitted in the speed ranges that have been calibrated by at least
67 percent.
The calibration process can be delayed by:
dynamic driving style
a road with lots of bends
frequent changes in load (only on vehicles with self-levelling suspension -> control of the air
springs/self-levelling suspension)
Detects drop in tyre pressure

The Run Flat Indicator records the wheel speeds using the wheel speed sensors from the DSC. The Run
Flat Indicator compares the speeds of the individual wheels and computes an average speed. In this way
the RPA is able to detect a loss of tyre pressure. (In the event of a tyre losing pressure, the tyre rolling
circumference of the affected tyre is also reduced.)
Visual and acoustic warning

A drop in tyre pressure in one tyre of approx. 30 % ± 10 % from the initial value is indicated by the Run Flat
Indicator telltale and warning lamp. In addition, an acoustic signal sounds.
Signal output: Depending on the model concerned, either via the instrument panel or the multi‐audio system
controller (M‐ASK) / Car Communication Computer (CCC).
Note: DSC fault
The sensors used by the Run Flat Indicator are all monitored by the DSC. If DSC detects a fault,
the Run Flat Indicator will also register a fault.
Actively reducing load on faulty wheel
> E70
If the Run Flat Indicator detects a puncture on one of the wheels on the rear axle, the self-levelling
suspension will actively reduce the load on the wheel concerned. The body may then assume a slight
incline. As soon as the puncture has been repaired and the Run Flat Indicator reinitialised, the incline will be
levelled out again. No repair work is needed on the air suspension itself.
Special conditions for system function
The following driving conditions may cause a delay in the warning being given in the event of a drop in tyre
pressure:
Heavy braking
Rapid acceleration
High rate of lateral acceleration
Cornering (in a tight corner)
Vehicle speed dropping below a minimum speed (the Run Flat Indicator only responds when a certain
minimum speed has been reached)
Large difference in slip (between axles or between wheel on one side of vehicle)
Initialisation not being completed in current speed range (see "Controls")
Winter conditions
Heavy changes in load (only vehicles with self-levelling suspension)
The following operating conditions may cause a delay in the warning being given in the event of a drop in
tyre pressure:
Driving with snow chains fitted
Driving with snow chains may impair the correct function of the Run Flat Indicator.
The system will work as normal again after the snow chains have been removed and the vehicle is driven
for a few minutes. (Repeat initialisation not necessary.)
Note: Do not perform initialisation when snow chains are fitted.
Initialisation and snow chains will cause incorrect adaptation values.
Trailer towing
Initialisation is required for trailer loads exceeding approx. 300 kg. Perform initialisation again after
attaching or removing the trailer.
Old/new tyres
Note: Only fit tyres with the same tread depth!
Avoid fitting tyres with greatly different tread depth (from approx. 2 millimetres) on one axle. The
different diameters mean that the correct operation of the Run Flat Indicator is no longer
guaranteed.
The following situations may cause unnecessary warnings:
Initialisation not completed after a tyre has been replaced (old/new tyres, summer/winter tyres, change in
direction of rotation, or replacement of single faulty tyre) tyre pressures have been changed
Tyres have different levels of wear
Frequent changes in load (only on vehicles with self-levelling suspension)
Tyres that have not been approved by BMW
Damaged tyres, even if no loss of tyre pressure can be detected (e.g. radial runout)
Tyre has changed slightly during the running-in phase (settling)
In the following cases, the system will not emit a warning despite a drop in tyre pressure being detected:
The same amount of pressure is lost in 2 or more tyres.
Drops in tyre pressures caused by diffusion and affecting all 4 tyres equally
If a tyre is damaged with a sudden loss of all pressure (tyre blowout, warning is given too late)
Operation
The Run Flat Indicator (RPA) is initialised using the following operating elements:
Run Flat Indicator button
On-board computer button on turn signal/high beam switch
With control centre in the Central Information Display (CID) with the controller
Caution! Always perform initialisation immediately after correcting the tyre pressure, especially if a wheel
is changed or the wheels are interchanged. Only check tyre pressures when the tyres are cold.
Set the tyres to the correct pressure before performing initialisation. During initialisation, the set
tyre pressure is taken as the initial value for the current set of wheels.
Correct the tyre pressures when the tyres are cold to prevent the data recorded from being
affected by temperature.
Caution! Responsibility resides with the driver at all times
Check tyre pressures regularly, at least twice a month and before embarking on lengthy journeys.
During initialisation, the set tyre pressure is taken as the initial value for the current set of tyres.
Initialise the Run Flat Indicator in the following situations:
If tyre pressure is changed
(tyre pressure is corrected or reset)
If the position of the tyres is changed (change of axles, wheels), even if the tyre pressure is not changed
If a tyre is changed or the wheels are interchanged
(e.g. old tyres for new tyres, summer tyres for winter tyres, etc.)
Start initialisation as follows:
Terminal 15 ON
(engine OFF or ON, do not pull away)
Vehicles with Run Flat Indicator button
Press and hold the Run Flat Indicator button until the Run Flat Indicator telltale and warning lamp
lights up yellow for a few seconds
Vehicles with on-board computer button (on-board computer function)
In the on-board computer function select "RPA" and "INIT" (liquid crystal display) with the rocker
switch on the turn signal/high beam switch. Press the on-board computer button to confirm.
Press and hold the on-board computer button for approx. 5 seconds, until a box with a tick appears
behind the "INIT" display.
> R56:
In the on-board computer function select "SET/INFO" (liquid crystal display in auxiliary instrument)
with the on-board computer button on the turn signal/high beam switch.
Press and hold the on-board computer button until the display changes
Press the on-board computer button repeatedly until the corresponding symbol and the word
"RESET" are displayed.
Press and hold the on-board computer button until a square with a tick appears.
Vehicles with Central Information Display
Initialisation is performed via the Central Information Display (CID) and controller.
Select "RPA" in the "Settings" menu and confirm.
Select "Set" and confirm.
Drive off
The end of the initialisation phase is not indicated.
Switch-on conditions
The Run Flat Indicator (RPA) is automatically activated when terminal 15 is switched ON. The Run Flat Indicator
cannot be switched off manually.
Observe the following information for service:
Diagnosis: ---
National-market version for US
A puncture is indicated as follows:
> E53, E83, E85, E86
Yellow Run Flat Indicator telltale and warning lamp without acoustic signal
> E60, E61, E63, E64, E65, E66, E70, E90, E91, E92, E93, R56
Yellow Run Flat Indicator telltale and warning lamp with acoustic signal
An RPA failure is indicated as follows:
Yellow Run Flat Indicator telltale and warning lamp without acoustic signal
Subject to change.
360299(469)
Run-flat tyre and inflation pressure warning systems
All
General
Warning systems
BMW AG offers two different systems which warn the driver whenever pressure drops in one or more tyres.
System Designation Measuring procedure

RDC Tyre pressure control (RDC) Pressure/temperature in the tyre
TPW Tyre Pressure Warning Comparison of wheel speeds
Emergency running systems

In addition to the warning systems, two run-flat systems are used which prevent the pressure in any tyre from
dropping to zero:
Components of the run-flat system with self-supporting tyres:
RDW (standard equipment) Tyre Pressure Warning

RDC (from 03/2000 can be selected as an alternative Tyre pressure control (RDC)
cost option))
SST Self Supporting Tyre
Disc wheel EH2 Disc wheel with Extended Hump 2
Elements of the run-flat system with integrated support ring:
Support ring Note:

In future, only for heavy high-security
vehicles (E38/3)
RDC (optional) Tyre pressure control (RDC)
Disc wheel H2 Standard disc wheel with Hump 2
RDC tyre pressure control

RDC system overview
The RDC continuously monitors the inflation pressure and the temperature in the tyres while in motion and
when at a standstill. The data are transmitted by message from the wheel electronics, are received by the
aerials located in the wheel arch and then sent to the RDC control unit. There, the data are compared against
stored limit values.
After correction of the inflation pressure with the engine stationary and the ignition switched on, the Set button
should be pressed for long enough (approx. 6 seconds) for the instrument panel (high equipment instrument
panel) to light up yellow LEDs for ”inflation pressure set” or (basic version instrument panel).
Whenever readings drop below these limit values, the driver is warned in two stages by the instrument panel:

Drop in tyre pressure from 0,2 to 0.4 bar Yellow LED on the basic version of the instrument
panel
or
Text: ”Check inflation pressure” on the high equipment
instrument panel
Gong: No
Drop of more than 0.4 bar in inflation pressure Red LED on the basic version of the instrument panel
or
Text: 'Puncture' on high equipment instrument panel
Gong: Yes
Benefits of the RDC
1. Safety - Early warning in response to rapid tyre pressure

loss
- Warning about tyre pressure losses due to natural
diffusion
2. Comfort - Consistent ride comfort

- Request for inflation pressure checks when required
3. Service life, economy - Minimisation of tyre wear

- Minimisation of fuel consumption
4. New developments - Facilitate use of run-flat tyres

- When using run-flat tyres spare wheel is dispensed
with (saving weight)
System structure of RDC
(1) RDC control unit (4) SET button
(2) Wheel electronics (4 pieces) (5) Display element

Wheel electronics for spare wheel (optional) (6) Anti-theft warning system
(3) Reception aerials (4 pieces) - Wiring harness
RDC control unit

Task:
evaluates the following messages from the wheel electronics:
- Tyre pressure
- Tyre air temperature
- Identification number (ID) of the wheel electronics
- Remaining service life of battery, wheel electronics
When required, issues a notice or a warning.
Wheel electronics with valve

Elements:
- Pressure sensor
- Temperature sensor
- Transmitter
Country-specific frequencies
- Voltage supply
Service life, approx. 7 years.
cannot be replaced
Installation position of wheel electronics in the disc wheel

The wheel electronics (1) are bolted to the valve (2) on the disc wheel (3)
Identifying feature:
Metal tyre valves
Note:
Due to the differences in disc wheel geometries, different valve
also need to be used. The valves are colour-coded. The
correct encoding can be found in the spare parts catalogue.
Aerial
Wheel electronics are located in every wheel arch.
Task:
receives messages to be forwarded to the RDC control unit.
SET button
Installed on the dashboard to the right of the steering wheel.
(E46: In the centre console).
Symbol: tyre cross section
Task:

Indicator lamp lights up yellow:
- Drop in tyre pressure of 0.2 to 0.4 bar
- Drop in pressure greater than 0.4 bar
Run Flat Indicator RDW

System overview of the RDW
The RDW measures the wheel speeds of all four wheels using the wheel speed sensors on the ABS/ASC or
the ABS/DSC system. This compares the wheel circumferential velocities of the diagonally opposed wheels
and their average speed.
As a consequence of a possible tyre pressure loss, the dynamic diameter of the wheel changes, and this also
alters the wheel speed.
A tyre pressure loss of 30 ± 10 % can be identified on all wheels above 15 km/h and up to maximum speed.
Whenever this value is exceeded, the driver is warned by the instrument panel in the following manner:

Tyre pressure loss of 30 ± 10 % red LED
Text: 'Tyre puncture'
Gong: Yes
The vehicle can only be moved at a max. speed of

80 km/h (50 mph)!
Note:
A careful driving style with low levels of
longitudinal and lateral acceleration helps
to extend the service life of the faulty
tyre.
Advantages of the RDW

With two exceptions, the same advantages apply to the RDW as to the RDC.
Exceptions:
- No warning of a natural tyre pressure loss in the tyre.
- The inflation pressure continues to need checking regularly every 14 days.
System structure RDW
(1) Wheel speed sensors on the ABS/ASC or the (3) SET button
ABS/DSC system
ASC = Automatic Stability Control DSC = Dynamic

Stability Control (4) Display element
(2) RDW control unit - Wiring harness
RDW control unit

Task:
- Evaluates wheel speeds.

- Issues a warning when required.
SET button
Installed on dashboard to right side of steering wheel. Symbol:
Tyre cross section with warning triangle
Task:

- Drop in inflation pressure 30 ± 10 %
Run-flat systems
Introduction
Run-flat tyres can also be driven with care following complete loss of tyre pressure for a certain distance. A
distinction is made between two different systems which satisfy these requirements:
- Run-flat system with self-supporting tyre
- Run-flat system with integrated support ring
Layout of the run-flat systems
Run-flat system with self-supporting tyre
The side walls on self-supporting tyres are reinforced. The tyres in conjunction with a special disc wheel can
also be driven carefully over a defined distance following a complete loss of tyre pressure.
Mobility remains assured up to a maximum speed of 80 km/h (50 mph) for the following distances, subject to a
careful and appropriate driving style:
Vehicle unladen max. 500 km

Roadster unladen less then 250 km
Vehicle fully laden max. 50 km
These self-supporting tyres require continuous monitoring of inflation pressure to warn the driver of any tyre
pressure loss while driving the vehicle. This is why these tyres are only offered in conjunction with the RDW
warning system, and from 03/2000 with RDC.
To prevent self-supporting tyres from jumping off the disc wheels when they suffer complete tyre pressure
loss, redesigned wheels with modified disc wheel humps but the same tyre seat (=standard disc wheel) need
to be fitted.
However, the new wheels are also suitable for normal tyres of any size.
Comparison between standard tyres and self-supporting tyres
Standard tyres depressurised / deflated
Self-supporting tyres depressurised / deflated

Devulcanised reinforcement (1) made of temperature-resistant
rubber compound
Disc wheels
H2-disc wheel (standard disc wheel) for run-flat system with integrated support ring
(1) Hump 2 on the standard disc wheel
EH2-disc wheel for run-flat system with self-supporting tyre
(1) Extended hump 2 on the disc wheel
(2) Wheel drop centre relocated a few millimetre inwards (pre-
centring on the outer side)
Note:
The new EH2-disc wheels (extended hump 2 inner and outer) will be used more frequently in
future by BMW because, also in conjunction with normal tyres, they make it much less likely for
the much feared loss of a tyre in response to tyre pressure loss, i.e. they move that tyre loss
point down to much lower inflation pressures.
Example: From at present 1.1 bar to 0.6 bar (X5- or Landrover disc wheel)
Run-flat system with integrated support ring:
(in future, preferably on heavy high-security vehicles)
The support ring is made of high-strength flexible plastic and is fitted into the tyre on a standard disc wheel. It is
only possible to dismantle the support ring using specialist tools approved by BMW, and cannot take place
until the tyre has been complete destroyed.
Run-flat systems with integrated support ring are specifically chosen for use in heavy-duty high-security
vehicles. Even in the event of total loss of tyre pressure, they allow these vehicles to leave a potential danger
area without having to reduce speed (escape situation).
There is the option of monitoring the inflation pressure with an RDC. The RDC is installed by pressing in the
support ring before installation.
Fitting a wheel with integrated support ring
Run-flat system with integrated support ring

(1) Tyre
(2) Support ring
Installation location for the RDC wheel electronics
(1) Wheel electronics
(2) Support ring
Other notes on the subject of ”inflation pressure warning systems and tyres with run-flat properties” - see
operating instructions.
For orders, a BMW Parts Department information bulletin is being produced.
36 04 99 (502)
Storage of wheels and tyres
All
Tyre / wheel storage, general
The storage of customer wheels is a service that almost goes without saying. For this reason, BMW Service
Technology should have a standard storage concept to prevent damage caused by incorrect storage.
Under the influence of sunlight, heat, humidity, moving air and ozone, the rubber in the tyre ages and loses
part of its strength and elasticity. For this reason, tyres must never be stored outdoors. If there is no
alternative to storing tyres outside for an extended period, the wheels/tyres must be clean and dry, and
covered with a waterproof material. In all cases, wheels / tyres must be protected from rain, snow and sunlight
but, due to the risk of corrosion, must not be stored in tyre bags. On the subject of tyre and wheel protection,
also refer to SI 36 01 88 (864).
Wheels / tyres with tyre pressure control (RDC) must not be treated using high pressure cleaners. General
information about the RDC - see SI 36 02 98 (377).
Requirements for the storage room
For storage in a sealed room, the following requirements apply:
cool 15...25 ° C / protect from heat sources or maintain a minimum

distance of1 metre from heat sources
dry Avoid water and condensationDo not bring into contact with
mineral-based greases
dark Protect against direct sunlight and artificial light with a high UV
content
moderate ventilation Avoid the ingress of oxygen and ozone
The storage room must therefore be cool and dry. There is no need for heating during the cold months. In
summer, keep doors and windows closed to prevent the ingress of draughts. Windows can also be painted
with protective paint.
The storage room must not contain any operating electrical machinery, welding equipment, switchgear etc.
because electrical sparks generate ozone which has an adverse impact on the surface of tyres (ozone
cracks).
Tyres should not be coated with oil, petrol or other mineral-based greases; these dissolve rubber and the tyre
becomes porous..
Tyre- / wheel preparation
1. Mark position of wheel on vehicle when removing wheel.
2. If possible, leave tyres on their wheels (wheel with tyre).
3. Correct inflation pressure and check every 2 months.
4. Ensure they are stored far enough off the ground. Never store wheels / tyres on the ground.
5. Fill in the stock reception slips. These must include the following details::
Type and size of tyre
Condition and tread depth
Customer address
Date and signature of customer
Requirements on the tyre / wheel mounting
A. Tyre fitted to wheel
Do not put down, ...

Note:
If there is no alternative to storing the wheels upright on the ground, increase their inflation
pressure to 3.5 bar.
... suspend instead, ...
... or stack them.

Note:
Use wooden pallets or similar supports.
B. Unfitted tyres
Do not stack, ...
... do not suspend, ...

... but instead put it down flat and turn it every 4 weeks.
Note:
Use standard shelving.
61 01 02 (005)
AGM battery
All models from E39
Introduction
In September 2002, the first so-called VRLA batteries, better known as AGM batteries came into use.
(VRLA means valve-regulated lead acid, i.e. lead acid battery with pressure relief valve; AGM stands for
absorbent glass mat, i.e. absorbent glass-fibre fleece)
AGM batteries are installed in models with electrical consumers that have high energy requirements.
Depending on the equipment fitted on the vehicle, AGM batteries (90 Ah) are currently installed in the following
development model series:
E39
E46
E53
E60, E61, E63, E64
E65, E66
E70
E81, E87, E90, E91, E92, E93
R56
AGM batteries will be fitted as standard as part of CO2 measures (e.g. intelligent alternator regulation or
automatic engine start/stop system).
The continuously increasing energy requirements of modern vehicle electrical systems demands ever more
efficient battery solutions. A modern luxury-class vehicle has some 100 actuator motors that have to be fed
with electrical current.
Then there are the safety, environmental and convenience elements, which are increasingly becoming
standard, for example:
Anti-lock brake system (ABS)
Dynamic Stability Control (DSC)
Electro-mechanical power steering (EPS)
Heated catalytic converter
Electronic chassis control
Air conditioning system
Navigation system
The slightly higher price and greater weight for the same size battery are fully compensated for by the following
benefits:
100% maintenance-free
Item Description Item Description

5 50% capacity limit
held freely in the battery housing.
Rather, 100% of the sulphuric acid is bound into the mats of the glass-fibre fleece (separators). For this
reason, no acid can escape if the battery housing is damaged. In addition, the AGM battery is sealed to be
airtight. This is possible because the gases are converted back into water by the permeability of the
separators.
AGM batteries can be recognised by the black housing and the lack of the so-called ”magic eye”. [more ...]

When handling AGM batteries, certain special factors must be taken into consideration with regard to battery
renewal and installation location.
General note: [more ...]
Diagnosis: ---
Subject to change.
00 07 04 (084)
BMW circuit diagrams on DVD:Wiring Diagram System
E46, E60, E61, E63, E64, E65, E66, E83, E85
Introduction
The wiring diagrams are of great assistance during diagnosis work. The wiring diagrams are displayed in the
BMW diagnosis system (on the DISplus and on the GT1).
Ever since the BMW diagnosis system DIS was introduced (”DIS” stands for ”Diagnosis and Information
System”, the system was introduced back in 1994) the dealer organisation has been calling for the ability to
display the wiring diagrams on a standard PC. For a long time, this was not possible due to technical system
issues. With the recently developed BMW Wiring Diagram System (WDS), it is now finally possible to meet
this request from the dealer organisation: All existing wiring diagrams from the BMW diagnosis system can now
be viewed using Microsoft Internet Explorer on any standard PC.
The BMW Wiring Diagram System is supplied on a DVD: The WDS-DVD receives the same wiring diagrams as
the BMW diagnosis system (DIS). Also the structure and appearance of the wiring diagrams are identical. This
makes orientation easy because BMW's DIS diagnosis system is a familiar one.
Advantage of the WDS-DVD: The employees in the workshop (mechanics, automotive electricians and
mechatronics specialists) can also view the wiring diagrams whenever the DIS testers in the workshop are
being used by others.
The 1st WDS-DVD was supplied shortly after publication of DIS-CD 37 in March 2004.[System overview ...]
In total, the WDS-DVD is published 4 times each year.
The WDS-DVD contains the following views:
Wiring graphic
Connector views
Pin assignments (for all control units with more than 8 pins)
Installation locations
Small symbols before the file name indicate whether this file is a wiring diagram, a set of connector views, pin
assignments or installation locations.
This 1st WDS-DVD contains the named scopes for the following series:
E46
E60, E61
E63, E64
E65, E66:
E83, E85
All named information is available in the following languages:
German
English UK
US English
French
Italian
Dutch
Portuguese
Swedish
Spanish
Note: The WDS-DVD does not replace the wiring diagrams on the DIS-CD.
For technical reasons, the WDS-DVD will be published slightly later than the DIS-CD.
System prerequisites
The WDS-DVD has the following system requirements:
Computer
Minimum requirements on the computer are as follows:
working memory (RAM): 32 MB
hard disk capacity: 13 MB
Drive: for DVD
Graphics card: min. graphics resolution of 800x600 pixels
Screen
Graphics resolution: at least 800x600 pixels
Printer
The system wiring diagrams can be printed out using any printer set up to run under Windows.
Operating system
The BMW Wiring Diagram System runs on the following operating systems:
Windows 2000
Windows NT 4.0 SP4 or higher (SP4 = Service Pack 4. e.g. if Windows NT has SP6 or higher,
because SP4 was absolutely required by Microsoft to be -compliant).
Windows XP
Internet browser
Microsoft Internet Explorer 5.5 or higher
Javascript and CSS enabled(CSS = Cascading Style Sheet, a type of layout template for html files)
Java support enabledwhen using the SUN Java Environment: at least version 1.4.1
Scripting of Java applets enabled
Adobe® SVG plugin 3.0 or higher installed(SVG = scalable vector graphic, i.e. a program for zooming
in to graphics) [more ...]
Note: System test for the computer can run under ”Technical prerequisites”.
At the bottom right-hand corner of the screen mask for ”Model-series selection”, there is the
button for ”Techn. prerequisites”. Click this button to open a view with a summary of system
requirements.
Using the link for ”Start system test” (left-hand column, centre) the computer checks to ensure
that all the required system prerequisites are present and correct.
System functions
The BMW Wiring Diagram System offers the following options ...
Zoom function
Search function
Languages
Paper printout
Zoom function
Unlike in the BMW diagnosis system, it is possible to zoom in on large wiring diagrams: Instead of having an
unchangeable scale to the left and right, or to top and bottom, the zoom function can be used to enlarge or
reduce the image. Various views can be selected, ranging from the system overview down to individual
detail. This provides a clear overview of the systems.
See 'Operation' section.
Search function
The BMW Wiring Diagram System offers the option of searching for specific components etc. (free text
search): Key in component and search for it).See 'Operation' section.
Languages
The desired language can be selected from several languages. See 'Operation' section.
Paper printout
The wiring diagrams (connector views, pin assignments, installation locations) in the displayed range (to the
right of the screen mask) can also be printed. See 'Operation' section.
Operation
The WDS-DVD has a Windows interface. That means that the WDS-DVD ”is familiar from initial point of contact”,
especially because the structure of wiring diagrams is already familiar from the BMW diagnosis system.
Nevertheless, here are a few details:
Order
Installation
Start WDS-DVD via Explorer
Select language.
Select model series
Search function
Zoom function
Printing
Order
Supply of the WDS-DVD is included in the media job lot of updates for the BMW diagnosis system. For in-
house use at BMW, an online application is being planned.
Installation
The WDS-DVD does not need to be installed. The WDS-DVD runs off the DVD in the browser. That means
that only the Adobe® SVG plugin needs to be installed (to display the wiring diagrams).[more ...]
Start WDS-DVD with the Internet browser

Start the WDS-DVD as follows:
1. Switch on PC and power it up.
2. Install WDS-DVD in the drive on your PC. Close the drive.The DVD is scanned automatically. The start
page for the ”WDS Wiring Diagram System” appears on screen.
Start WDS-DVD via Internet Explorer
If the WDS-DVD is not scanned in automatically, the WDS-DVD can be started manual via the
Windows Internet Explorer in the following manner:
1. Open Windows Internet Explorer.
2. In Windows Internet Explorer, double-click the DVD drive.
3. In the "Search" menu, search for the following data: index.htm.
4. Double-click the file ”index.htm”. The DVD is scanned.The start page for the ”WDS Wiring Diagram
System” appears on screen.
Select language.
Click the desired language on the start page of the ”WDS Wiring Diagram System”.
The screen mask for ”Model-series selection” appears with the following request: ”Please select a series.”
Select model series

In the screen mask entitled ”Model-series selection”, click the desired series.The window for the desired
series then opens.
The contents page appears on the left side (= the ”navigation tree”).
On the right side are ”Notes on operation and navigation” in the WDS-DVD.
Search function
Searches are conducted via a selection of model series and selection in the navigation tree or via keyed in
designations (text search, e.g. for "window").
Search via a selection of model series and selection in the navigation tree
1. Top left in the function bar, click the ”Series” button.The screen mask for ”Model-series selection”
is opened.
2. Click the desired series. The window for the desired series then opens. The contents page
appears on the left side of the window (= the ”navigation tree”).
3. Click the "+" button before an entry. The sub-folders are opened.
4. Click the desired document. The document is opened.
Text search
For text searches, the term being sought is keyed into the input box. During this, partial terms are also
found. If for example, 'windscreen' is keyed in, the system will also find 'windscreen wipers'.
There are 2 options for the text search function:
the desired term is sought for throughout the entire navigation tree.
the desired term is sought for in a single wiring diagram.
The text search function is called up in the navigation tree as follows:
1. bottom left in the toolbar, key the search term into the input field.
2. Click the 'Search' button.The text search commences. The text search function also locates
keywords with similar typography to the term keyed in.
”Hits” are highlighted in dark on the contents list (= ”navigation tree”).
3. Click the "+" button before the 'hit'. The sub-folders are opened. Click the desired document. The
document is opened.
4. If there are several hits, click the 'Next' button to display other hits.
Initiate the text search in a wiring diagram via the context menu (right mouse button).[more ...]
Zoom function
'Zoom' can be used as follows to switch between the system overview with all its components and displays
of individual sections of the wiring diagram:
Enlarge view: At the bottom, in the centre of the toolbar, view the symbol with the magnifying glass and
click the + symbol. (or: press and hold down the 'CTRL' key)
Click the wiring graphic.
The screen mask is enlarged. More details become visible.
Reduce size of view At the bottom, in the centre of the toolbar, view the symbol with the magnifying
glass and click the minus ('-') symbol. (or: Press and hold down the 'CTRL' and 'SHIFT' keys = ”selector
button” at the same time)
Click the wiring graphic.
The view is reduced in size. Fewer details, therefore a better overview of the system.
Print
1. Top left in the function bar, click the ”Print” button. The "Print" window opens up. Select printer, pages,
number of copies etc., as also under Windows.
2. In the 'Print' window, click the 'Print' button.The indication range (right side of screen mask) is printed
out.
A complete overview of all buttons can be found in the annex. [more ...]
Diagnosis: ---
Car & Key Memory: ‐‐‐ ---
National-market version for US
US English version is available.
61 03 05 (144)
Bus structures
All models from E38 and MINI
Introduction
In the vehicles of today, components and control units are networked by means of data buses. Data buses
are capable of transmitting messages and signals.
The connected control units only read off those messages and signals that are of relevance to their operation.
Most buses are CAN buses (CAN: Controller Area Network).
A fibre-optic cable is used for navigation and entertainment: The MOST bus (MOST = ”Media Oriented System
Transport”).
It has its own data wire for diagnosis: the diagnostics cable, also known as the ”K-line”
[Overview of BMW data buses ...]
This SI Technology bulletin (SBT) contains system overviews of bus structures for the following model series:
E38 [system overview ...] (7-Series, manufacturing period from 1994 to 2001)
E52 [system overview ...] (Z8, manufacturing period from 1999 to 2003)
E53 [system overview ...] (X5, manufacturing period from 1999 until 2006)
E60, E61, E63, E64
> E60, E61, E63, E64 from 03/2007: [System overview ...]
> E60, E61, E63, E64 from 09/2005 until 03/2007: [system overview ...]
> E60, E61, E63, E64 from 03/2005 until 09/2005: [system overview ...]
> E60, E61, E63, E64 until 03/2005: [system overview ...]
E65, E66
> E65 and E66 from 03/2005: [system overview ...]
> E65 and E66 from 03/2004 until 03/2005: [system overview ...]
> E65 and E66 until 03/2004: [system overview ...]
E70 [system overview ...] (X5, start of series production 2006)
E83
> E83 [system overview ...] (X3, start of series production 2004 until 09/2006)
> E83 from 09/2006 [system overview ...]
E85, E86
> E85 (Z4), start of series production 2002 until 01/2006: [system overview ...]
> E85, E86 from 01/2006: [system overview ...]
E81, E82, E87 [system overview ...] (1-Series, start of series production 2004)
E90, E91, E92, E93 [system overview ...] (3-Series, start of series production 2005)
R50, R52, R53 [system overview ...] (MINI and MINI Convertible, start of series production 2001)
R55, R56 [system overview ...] (start of series production 2006)
This SI Technology bulletin (SBT) also contains a section with frequently asked questions.
[more ...]
Note: Abbreviations for control unit names
In the overviews of bus structures, all diagnosis and programming control units are indicated by
abbreviations.
The abbreviations used for the control units are listed in alphabetical order and explained in the SI
technology bulleting ”abbreviations.
[more ...] and
[for more information, please refer to SI Technology (SBT) 00 01 03 035]
The following control units are numbered:
Control units that cannot be programmed and cannot be encoded and which do not appear
in the quick test.
These control units do not have an abbreviation, just a number.
Control units with control unit designation from the time before electrical system 2000:
Besides the abbreviation, these control units have a number for entering in the table.
On the history of control unit designations:
Since the start of series production of the E65 (electrical system 2000), the control unit
designations have been harmonised. Earlier model series have varying control unit
designations.
For technical reasons associated with the system, these control units have not been
renamed.
This is because: These control unit designations appear in the quick test on the
BMW diagnosis system.
Buses and control units in the E60, E61, E63, E64
In the E60, the K-CAN S and K-CAN P from the E65, E66 have been combined to form the K-CAN.
This means the E60 has the following buses: byteflight (until 09/2005), K-CAN, MOST, F-CAN, PT-CAN plus a
local CAN (for the engine management system).
The central interface for exchanging data between buses is the safety and gateway module (SGM).
Note: Modifications in the bus structures on the E60, E61, E63, E64 from 03/2007
From March 2007, the bus structures are modified as follows:
The D-CAN is now also integrated:
D-CAN (diagnosis-on CAN) supersedes the previous diagnosis interface in all parts of the
world.
The GWS is now also integrated:
A new control unit has been integrated on the PT-CAN for selecting the drive position in the
automatic transmission.
GWS: Gear selector switch
With the gear selector switch, the automatic transmission is no longer actuated
mechanically, but rather electronically.
The TLC is now also integrated:
A new control unit has been integrated on the PT-CAN for the driver assistance system.
TLC: Track lane control
Track lane control supports the driver by vibrating the steering wheel to warn him if the
vehicle unexpectedly drifts off of the regular course, prompting him to countersteer.
The LDM and LRR are also integrated:
With the introduction of active cruise control with stop&go function, 2 new control unit are
integrated for cruise control:
LDM: Longitudinal dynamics management
LRR: Long range sensor
The control unit for longitudinal dynamics management (LDM control unit) is connected to the
PT-CAN.
The long range sensor is connected to the LDM and the close-range sensors by the new
sub-bus. The sub-bus is called the sensor CAN (S-CAN).
> E60, E61, E63, E64 from 03/2007: Buses and control units: [System overview ...]
From September 2005, the bus structures are modified as follows:
No byteflight data bus
The SZL control unit is connected to the PT-CAN and no longer to the byteflight.
As before, the SZL control unit is connected to the F-CAN.
Following control units are dropped together with the byteflight:
SBSL: B-pillar satellite, left
SBSR: B-pillar satellite, right
TMBF: Door module, front-passenger
TMFA: Door module, driver
ACSM is added.
The crash safety system is controlled by a new control unit:
ACSM: crash safety module
The ACSM control unit is on the K-CAN.
(”ACSM” = Advanced Crash Safety Module or Management)
[for further information, please refer to SI Technology (SBT) 65 05 05 138]
ALBBF and ALBFA are added.
2 new control units for the active backrest width adjustment are added on the PT-CAN.
ALBBF: Active seat back width, front passenger seat
ALBFA: Active seat back width, driver's seat
CA is added.
A control unit for comfort access is added on the K-CAN.
CA: Comfort Access
KGM is added.
As of September 2005, the data interface for the buses is the body-gateway module (KGM).
The previous data interface for the buses, the safety and gateway module (SGM) has been
dropped.
The following functions are integrated in the KGM control unit:
Data interface for buses
Outside door handle electronics
Vehicle centre satellite
micro-power module
IBS: Intelligent battery sensor
The IBS is connected via the bit-serial data interface (BSD) to the engine control unit. The
IBS has been part of the power supply on the BMW 5-Series since start of series
production.
FLA is added.
A new control unit for the main-beam assistant is added on the K-CAN:
FLA: Main-beam assistant
For US vehicles: IBOC is added.
For US vehicles, a control unit is added to the MOST for analogue and digital radio reception.
IBOC: Digital tuner US
For Korea vehicles: KNAV is added.
A control unit for the navigation system is added for vehicle in Korea.
KNAV: Korea navigation system
The KNAV control unit is connected to the MOST.
A new control unit for the night vision assistant is added on the K-CAN:
NVE: night vision electronics
MPM dropped.
No micro-power module (MPM) on the K-CAN. The KGM control unit performs the functions
of the MPM.
For US vehicles: RDC is added.
For US vehicles, a new control unit added on the K-CAN for monitoring tyre pressure has
been.
RDC: Tyre pressure control
> E60, E61, E63, E64 from 09/2005 until 03/2007: Buses and control units: [System overview ...]
From March 2005, the bus structures are modified as follows:
AHL discontinued:
From March 2005, the AHL control unit (adaptive headlights) is integrated into the light
module. The light module is connected to the K-CAN and the PT-CAN.
The VTG is now also integrated: For the E60 and E61, an all-wheel drive vehicle is available.
The control unit for the xDrive on the E60 and E61 is known as the VTG: Transfer case.
> E60, E61, E63, E64 from 03/2005 until 09/2005: Buses and control units: [System overview ...]
Note: Original version: Buses and control units on E60, E61 E63, E64 up to 03/2005
To support the workshops, the predecessor version of the bus structures on the E60 are also
described below:
> E60, E61, E63, E64 until 03/2005: Buses and control units: [System overview ...]
Buses and control units in the E65 and E66

The main buses in the E65 and E66 are called: K-CAN P, K-CAN S, MOST, byteflight, Local CAN, PT-CAN.
Note: Modifications to the bus structures for the E65 and E66 from 03/2005
From March 2005, the AHL control unit (adaptive headlights) is integrated into the light module.
The light module is connected to the K-CAN S and the PT-CAN.
> E65 and E66 from 03/2005: Buses and control units: [System overview ...]
Note: Predecessor version: Buses and control units on E65, E66 from 03/2004
To support the workshops, a description of the predecessor version of the bus structures on the
E65 and E66 is also provided:
The key modification compared to the original version of the bus structures on the E65 and E66
is:
SIM and ZGM have been combined to create the SGM. The SGM is the central data interface for
all buses and control units.
(SIM: safety and information module)
(ZGM: central gateway module)
(SGM: safety and gateway module)
> E65 and E66 from 03/2004 to 03/2005: Buses and control units: [System overview ...]
Note: Original version: Buses and control units on E65, E66 up to 03/2004
To support the workshops, the original version of the bus structures on the E65 and E66 is also
available:
In the original version, the E65, E66 had the two control units SIM and ZGM.
SIM: safety and information module
The SIM was the data interface for the control units on the byteflight data bus.
ZGM: Central gateway module
The ZGM is the central data interface for all buses and control units.
> E65 and E66 up to 03/2004: Buses and control units: [System overview ...]
Buses and control units in the E70
The important buses in the E70 are called: K-CAN, MOST, PT-CAN, F-CAN, FlexRay.
FlexRay is a new communication system that offers extremely efficient, real time data transfer between the
electrical and mechatronic components in the vehicle. FlexRay has a data transfer rate of 10 MBit/s.
FlexRay is used for data exchange between the VDM control unit and the shock absorber satellites.
CHAMP: On the US national version, instead of the multi-audio system controller (M-ASK), the Central
Headset And Multimedia Platform (CHAMP) operates as the BMW ”Professional” radio. In contrast to M-ASK,
CHAMP does not have a navigation system.
> E70: Buses and control units [system overview ...]
Buses and control units in E81, E82, E87
The important buses in the E87 are called: K-CAN, MOST, PT-CAN and F-CAN.
The MOST, the innovation in the bus structure on the E65 and E66, is now also used in the E81, E82, E87.
The central interface for data transmission is the junction box electronics (JBE) in the junction box.
> E81, E82, E87: Buses and control units [system overview ...]
Buses and control units on the E90, E91, E92, E93
The most important buses on the E90, E91, E92, E93 are: K-CAN, MOST, PT-CAN, F-CAN.
The new feature is that the footwell module (FRM) is connected to the PT-CAN. This is because:
The adaptive headlights are integrated into the footwell module. The adaptive headlights need the high-
speed PT-CAN.
The longitudinal dynamics management sends the signal for the brake light on the PT-CAN.
> E90, E91, E92, E93: Buses and control units: [system overview ...]
Buses and control units on the R50, R52, R53
The most important buses on the R50, R52, R53 are: K-bus, PT-CAN.
The central interface for data transfer is the instrument cluster (KOMBI).
> R50, R52, R53: Buses and control units: [system overview ...]
Buses and control units in the R55, R56
The most important buses on the R55, R56 are: K-CAN, MOST, PT-CAN and F-CAN.
The central interface for data transmission is the junction box electronics (JBE) in the junction box.
> R55, R56: Buses and control units: [system overview ...]

Programming: ---
Subject to change.
61 01 98 (293)
Car and Key Memory
E46
None of the function and system descriptions are covered by an update service.
Table of contents
1.0 Introduction
2.0 Recommendation
3.0 Note national-market versions and equipment ranges!
4.0 What is ”Car & Key Memory”?
4.1 Car Memory
4.2 Key Memory
5.0 Definition of ”Car and Key Memory”
6.0 Variable settings by the customer
6.1 Seat/mirror memory
6.2 Heating / air conditioning / ventilation
7.0 Identification of keys
8.0 Key initialisation - reorder
9.0 Notes and tips on ”Car & Key Memory”
9.1 Test drive with vehicles set up with ”Car & Key Memory”
9.2 Explanation of symbols and terms
Overview of functions of ”Car & Key Memory” for E46 (status: April 1998) (identical to IDC 005/98_12)
Detailed description with special features and the customer benefits of all settings, "explanations of the
functions for Car & Key Memory” (status: April 1998)”
1.0 Introduction
Market analyses show that today's customer, compared to previous times, now expects a much higher
standard from his/her car. Customers wish to own a vehicle customised to their personal wishes.
Through consistent further development of technology for the individual electronic systems in the vehicle and
above all through the rising level of multiplexing between those electronic systems, the new E46 is the first
vehicle to give customers the option of choosing individual preferences from a wide range of electronically
controlled functions and to set up a vehicle in accordance with personal preferences.
The ”Car and Key Memory” program opens up new vistas of customer support options within the BMW dealer
organisation. BMW views ”Car & Key Memory” not only as an example of competitive edge, but also a way of
enhancing customer loyalty to the BMW brand and to its dealers.
This BMW Service Technology document is intended as a piece of basic information for the dealer
organisation and is intended to provide an overview of ”Car & Key Memory”.
The programs for ”Car & Key Memory” are integrated in the BMW diagnosis CD-ROM and will be supplied for
the first time with the diagnosis CD-ROM V13 in April 1998. ”Car & Key Memory” settings are carried out by the
BMW DIS diagnosis system and by the new MoDiC in the BMW dealer organisation.
At present, the ”Car & Key Memory” program is only intended for the E46. Work is progressing on extending it
to the E38 and E39 and the scheduled launch date is the end of 1998.
2.0 Recommendation
The subject of ”Car & Key Memory” opens up new prospects in the BMW dealer organisation for dealers and
customers. However, this does call for a comparison of information between Sales, Service, Workshop and
Warranty within the dealer organisation.
Customers should be familiarised with details of the ”Car & Key Memory” right from the initial sales
conversation. The seller should document the settings desired by the customer to enable these customer
wishes to be implemented in the pre-delivery check.
”Car & Key Memory” settings should always be viewed as billable items. The first setting, part of the pre-
delivery check and any further correction should be offered as a service, i.e. as a discretionary item. It is left to
the individual dealer organisation to decide whether or not to bill for every subsequent adjustment.
As a standard basis and for internal billing purposes for payroll costs incurred within the dealer organisation,
the following flat rate units (FRUs) were defined for ”Car & Key Memory”:
For the setting of up to 5 functions: 4 FRU, FRU number: 61 00 050 For the next 5 settings: 1 FRU, FRU
number: 61 00 560
N.B.: settings made using ”Car & Key Memory” do not rectify technical faults and are therefore not covered by
the warranty.
3.0 Note national-market versions and equipment ranges!
The available ”Car & Key Memory” settings depend on the national-market version and on the equipment
range. By the same token, country-specific legislative requirements and insurance requirements have an
impact on the possible settings.
The ”Car & Key Memory” program takes the fullest possible account of this highly complex subject area and,
as a consequence, the functions connected to each vehicle are only ever the ones that can be displayed and
set.
Annex 2 contains a more detailed description of the ”Car & Key Memory” settings. There is a brief description
in Annex 1.
4.0 What is ”Car & Key Memory”?
The ”Car & Key Memory” program implements individual settings wished for by the customer in the electronic
vehicle systems. No safety or registration-related points are set (i.e. these lie outside the scope). These are
implemented as before using the familiar programs for ”Encoding body/chassis and suspension” and
”Programming the drive”.
The settings for ”Car & Key Memory” are implemented by the dealer.
4.1 ”Car Memory”
In ”Car Memory”, settings are carried out which relate to the vehicle. These setting are independent of the key
used and take effect when unlocking with the master key and when unlocking via the door lock.
4.2 ”Key Memory”
Settings made using ”Key Memory” are assigned a defined key with master key. All required data are saved in
the relevant control units. The ”Key Memory” settings can only be assigned to keys with remote control
capability (i.e. to master keys). As standard, 2 master keys are supplied to customers. Up to 4 keys with
master key settings can be assigned to a vehicle.
N.B.: When unlocking with a master key, the key is identified by the vehicle. Identification is forwarded via the
bus systems to the electronic systems in the vehicle which enable the relevant settings.
5.0 Definition of ”Car & Key Memory”
”Car & Key Memory” settings can be restricted uniquely to ”Encoding of body/chassis and suspension” and
”Programming the drive”.
The original motivation for developing the ”Car & Key Memory” was to meet the customer's wishes for
individuality and to use the technology and tools available within the dealer organisation to cover a wide range
of customer requests.
"Car & Key Memory: All settings performed using the ”Car & Key Memory” function are only performed using
DIS or MoDiC. No tools are required. No control unit needs to be removed, and no E-box cover etc. needs to
be dismantled.
The settings are carried out to customer request or on a recommendation from a dealer.
"Encoding/programming": ”Encoding and programming” is performed when repairs are required, and control
units and/or vehicle components need to be dismantled. Software/hardware is replaced or supplemented and,
in some cases, an adhesive label needs to be attached.
The programs ”Encoding body/chassis and suspension” and ”Programming of drives” were developed for
various reasons, including to cover as many variants as possible with a single control unit to cover instances
of repair work, where the new control unit simply needs to be adapted to suit the country of use and/or the
equipment specification of the vehicle.
6.0 Variable settings by the customer
In addition to the functions described in Annexes 1 and 2, which can be set by the dealer using DIS and MoDiC,
there is a system in ”Car Memory” and a system in ”Key Memory”, in which key-specific functions can be
changed individually by customers.
6.1 Seat/mirror memory - ”Car Memory”
If ”Car Memory” is set for the function ”Seat/mirror memory” ”For unlocking” or ”For door opening”, the seat
position individually set by the customer is saved in the control unit using the number of key with master key
with which the vehicle was unlocked.. The seat position is reactivated whenever the vehicle is unlocked using
the key with remote control, i.e. the master key. The type and nature of seat positioning is dependent on the
aforementioned setting.
If "not active" is selected, no key-specific seat positioning is possible.
In the E46, the ”Mirror Memory” function is not supported at this time.
The seat position that can be saved for each seat at the touch of a button is independent of the ”Car & Key
Memory” settings.
6.2 Heating/air-conditioning/ventilation - ”Key Memory”
- Individually selected button settings on the IHKA controls are assigned to the master key which was used
to unlock the vehicle. The dealer does not need to perform any pre-adjustment. Settings for ”Individual air
distribution” (1), ”Automatic air distribution” (2) and temperature and blower setting (3) are saved in a
customer-specific manner (see graphic).
7.0 Identification of the master key

A total of 4 master keys can be provided, each with different functions. To enable individual keys to be
identified, each must be colour-coded on the back. Labels for this purpose are supplied with the vehicle.
These adhesive labels can be sourced by quoting BMW part number 66 12 8 381 059 via the standard part
ordering channel.
To enable the master keys to be distinguished from one another, it is advisable to identify the keys as follows:
Key 1 Adhesive label, grey

Key2 Adhesive label, green
Key3 Adhesive label, red
Key4 Adhesive label, blue
N.B.: The numbers on the key for the ”Car & Key Memory” setting have no relation to one another and can
differ from the numbers used to lock the keys in the EWS diagnostic program.
8.0 Key initialisation - reorder
As a general rule, the two master keys are initialised before being supplied to the customer. If this is not the
case, or if a third or fourth master has been ordered, proceed as follows:
Reinitialise master keys that have not been initialised - see operating instructions.
The initialisation sequence depends on the numbering of the keys.
The first key to be initialised automatically receives the number 1 and we recommend that this master key
should receive the grey adhesive label.
9.0 Notes and tips on ”Car & Key Memory”
9.1 Test drive with vehicles set up with ”Car & Key Memory”
On a test drive, as a rule, the seat position needs to be changed by the workshop employee.
To avoid changes to customer-specific settings (seat/mirror memory and heating / air conditioning /
ventilation), the vehicle must be unlocked mechanically by inserting a key in the door lock. The seat position
can now be adjusted.
If the customer opens his vehicle in the usual manner using the master key, the last key-specific settings
assigned to his key are enabled again.
The settings performed by the workshop personnel are not saved using this procedure.
9.2 Explanation of symbols and terms
”Factory setting” If ”factory setting” is selected, the vehicle is set up independently of individually set
functions acc. to the ZCS (delivery status ex factory). This entails the loss of all settings which differ from the
”factory setting”.
N.B.: If the passenger seat occupancy detector on the front passenger seat was disabled, this must be
performed again after running a ”factory setting” using the ”encoding body/chassis and suspension” program.
Deactivation of the passenger seat occupancy detector is not documented in the ZCS. Deactivation of an
airbag is documented in the ZCS and remains in place after a ”factory setting”.
”Reject selection” If ”Reject selection” is selected, the entire ”Wish list” individually compiled by the sales
representative is deleted. After that, new settings can be chosen.
”Setting up vehicle” If ”Setting up vehicle” is selected, the individual functions compiled on the ”Wish list” is set
in the individual systems. Before carrying out the setting process, the full range of settings can be printed out
using ”Hardcopy”.
9.3 Symbols for the identification of individual functions in ”Car & Key Memory”
In the program run, new symbols appear before the various range of adjustments available for the different
functions:
Symbol ”*” for the identification of a ”factory setting” The ”*” symbol shows that the designated setting for
”factory setting” corresponds to the Central Encoding Key (ZCS).
Symbol ”=” for designation of an ”Actual setting” The ”=” symbol shows that the designated vehicle function
is currently enabled. If no ”*” can be found among the adjustment options, the ”Actual setting” matches the
”Factory setting”.
Symbol ”>” for the identification of a ”Nominal setting” The symbol ”>” shows that this range of adjustments
was selected and needs to be set. If the ”>” symbol is visible, you are in the ”Setting phase” - a "Wish list"
exists.
63 02 03 007
Adaptive Headlights
Note: Option 524 only in conjunction with optional equipment 522.

Optional equipment 524 ”Adaptive headlights” is only available in conjunction with optional
equipment 522 ”Xenon light for dipped and main-beam headlights”.
Note: EU approval for optional equipment 522 only in conjunction with optional equipment 502.
Optional equipment 522 ”Xenon light for dipped and main-beam headlights” is only available
together with optional equipment 502 ”Headlight cleaning system” (in countries subject to EU
approval).
Note: ALC => AHL
The development code for the adaptive headlights was ”ALC”.ALC stood for ”Adaptive Light
Control”. The marketing and sales designation for optional equipment 524 in English-language
markets is ”adaptive headlights”, abbreviated to ”AHL”. Diagnosis and technical vehicle
documentation therefore use the abbreviation ”AHL”.However, ”ALC” is still used on some control
units and in the EPC (Electronic Parts Catalogue).
Introduction
The Adaptive Headlight system turns the bi‐xenon headlights towards the inside of a bend when cornering.
This improves illumination of the curve of the road. Visibility is therefore improved. When cornering, the
occupant is not looking into a ”black hole” - instead, the adaptive headlights allow the driver to see the curve of
the road.
This BMW Service Technology bulletin (SBT) describes the adaptive headlights for the following model series:
> E60, E61, E63, E64 up to 03/2005
The system overview applies accordingly for the E65 and E66 up to 03/2005.
> E60, E61, E63, E64 from 03/2005 until 09/2005

The system overview applies accordingly for the E65 and E66 from 03/2005.
Note: AHL control unit discontinued from 03/2005.
From 03/2005, the AHL control unit software is integrated into the light module on the
E60, E61, E63, E64, E65 and E66. The AHL control unit is no longer fitted.
> E60, E61, E63, E64 from 09/2005
The vehicle electrical system was changed from 09/2005. As a result of the changeover, several control
units were discontinued and some control unit functions were integrated into new control units.
> E70, E71, E72

The cornering light function is new on the E70 from the series launch.
The cornering light gives the area next to the roadway additional illumination when you are turning or
cornering (driving in tight bends). They are also active when you park the vehicle. Depending on the
country concerned, the cornering light are switched on while cornering.
> E81, E82, E87, E88, E89, E90, E91, E92, E93
For the E81, E82, E88, E89, E92, E93 from series launch and for the E87 from 03/2007, the cornering light
function is new.
Note: Cornering light in conjunction with optional extra 524
Cornering lights are a subfunction of optional equipment 524 ”Adaptive headlights”. Bi‐xenon
headlights are standard equipment on the E92, E93. Optional equipment 524 is standard on the
US version.
Note: AHL components on E46, E53 and E83
There is a separate system description for the adaptive headlights on the E46, E53, E83 . [more in
the vehicle engineering diagnosis (FTD) 63 03 03 047]
Note: AHL components on the E63, E64
The E63, E64 has a zero-position sensor.
[more in the vehicle engineering diagnosis (FTD) 63 03 03 047]
Otherwise, the E63 and E64 are the same as the other 5-Series models.
Note: AHL components on the E70, E71, E72, E81, E82, E87, E88, E89, E90, E91, E92, E93
The adaptive headlights largely correspond to the adaptive headlights of the E60, E61, E63, E64
and E65, E66:
The E70, E71, E72, E81, E82,E87, E88, E89, E90, E91, E92, E93 has a zero-position sensor.
The E70, E71, E72, E81, E82, E87, E88, E89, E90, E91, E92, E93 uses the FRM (footwell
module) as a control unit for the exterior lights. The footwell module contains the functions of
the light module, AHL control unit and the basic module (or body general module).
[more in the vehicle engineering diagnosis (FTD) 61 04 04 094]
The following components and control units provide signals for the adaptive headlight system:
CAS: Car Access System
The Car Access System supplies signals for the terminal control (e.g. terminal 15 ON).The adaptive
headlights control unit is activated when terminal 15 is switched ON.
Light switch
The rotary switch for the side lights and low-beam headlights differs depending on the vehicle equipment
level (adaptive headlights, automatic driving lights control, automatic or manual headlight beam throw
adjustment). For the adaptive headlights function to operate, the light switch position must be set to ”A”
(”A” = ”automatic driving lights control” and ”adaptive headlights”). [more ...]
Turn signal/high beam switch
The high-beam headlights are switched on and off by the turn signal/high beam switch (by pressing or
pulling the switch). The adaptive headlights function operates with both low-beam headlight and high-
beam headlights. [more ...]
SZL: Steering column switch cluster
The SZL control unit forwards the signals from the turn signal/high beam switch to the adaptive headlights
control unit.
> E60, E61, E63, E64, E65 and E66
[more ...]
> E70, E71, E72, E81,E82, E87,E88, E89, E90, E91, E92, E93
The steering column switch cluster forwards the signals from the turn signal/high beam switch to the
footwell module (FRM). [more in the vehicle engineering diagnosis (FTD) 61 07 04 103]
, ride height sensors

If the optional equipment ”Adaptive headlights” is fitted, the adaptive headlights control unit evaluates the
signals from the ride height sensors. Reason: the adaptive headlights control unit also controls the
automatic headlight beam throw adjustment.
The automatic headlight beam throw adjustment feature adjusts the height of the headlights to
compensate for variations in the vehicle inclination angle (e.g. when the vehicle is laden, and under
braking and acceleration in dynamics driving situations).
[more ...]
Brake light switch
If the optional equipment ”Adaptive headlights” is fitted, the signals from the brake light switch are read by
the adaptive headlights control unit. In addition, the brake light switch signal is also a signal for automatic
headlight beam throw adjustment, see above: Ride height sensors.
Position sensor
> E60, E61> E65, E66
Hella headlights have a position sensor.
The position sensor in the swivel module for the bi-xenon headlights supplies a signal for the horizontal
movement of the headlights.
[more ...]
Zero-position sensor
> E63, E64
> E70, E71, E81, E82, E87, E88, E89, E90, E91, E92, E93
Automotive Lighting headlights, previously Bosch, have a zero-position sensor.
The zero-position sensor registers the horizontal movement of the headlight.
[more ...]
transmission control unit or reversing light switch
When reverse gear is engaged, the headlights are moved to the straight-ahead position.
On vehicles with automatic transmission, the EGS control unit provides the ”Reverse gear engaged”
signal. (EGS: electronic transmission control).
On vehicles with manual gearboxes, the signal is supplied by the reversing light switch.
Rain/light sensor for automatic driving lights control
The rain/light sensor measures the ambient brightness outside the vehicle.
In twilight conditions, the rain/light sensor transmits the message ”Twilight” so that the
automatic headlight beam throw adjustment can activate low-beam headlights. The headlights are
tilted up and down as required, but they are not yet moved towards the bend in the road.
In darkness, the rain/light sensor transmits the message ”Darkness”. The adaptive headlights are
then activated when the vehicle is cornering. The headlights are moved to the left or right:
[more ...]
Steering angle sensor and DSC sensor
The steering angle sensor and DSC sensor (DSC = Dynamic Stability Control) supply signals for the
adaptive headlights to the adaptive headlights control unit. These signals are evaluated as follows,
depending on the driving speed:
Driving speed up to 30 km/h:The adaptive headlights function is controlled using the information from
the steering angle sensor (in the steering column switch cluster).
Driving speed between 30 km/h and 50 km/h: In the 30 to 50 km/h speed range, there is a
continuous transition in signal evaluation: from the signal evaluation sent by the steering angle
sensor to signal evaluation sent by the yaw sensor (in the DSC sensor).
In extreme dynamics driving situations, e.g. if the vehicle starts to skid or fishtail, even at driving
speeds of less than 50 km/h, the signals from the yaw sensor are considered. If the vehicle starts
to skid or fishtail, the headlights will move to the straight-ahead position. The headlights are not
moved until the vehicle has stabilised.
Driving speed over 50 km/h:At speeds upwards of 50 km/h, the signals from the yaw sensor (in the
DSC sensor) form the primary basis for control of the adaptive headlights function.
Reason: For a constant cornering radius, the required steering angle increases disproportionately
with speed. In addition, the required steering angle also depends on the coefficient of friction of the
roadway. Yaw rate is directly proportional to speed. For this reason, the yaw rate is always the most
suitable measure for controlling the adaptive headlights at high speeds.
Even at high speeds, however, the steering angle sensor signal is used to detect (predict) the
driver's choicein advance. This prediction is important: The yaw-rate signal is not supplied until the
vehicle has responded to the steering wheel movement.
The steering angle sensor signal is disabled so that rapid, momentary steering wheel adjustments
(so-called “surging”) do not affect the adaptive headlights function.
A number of control units are involved in the adaptive headlights system (see above: CAS, EGS,
SZL).Depending on the model series and model revision concerned, the adaptive headlights are actuated by
the following control units:
AHL: Adaptive Headlights
> E60, E61, E63, E64, E65, E66 until 03/2005
The AHL control unit actuates the adaptive headlights.
For safety reasons, the AHL control unit is also responsible for the automatic headlight beam throw
adjustment. Reason: Oncoming traffic may not be dazzled by the adaptive headlights. If a headlight sticks
in an unfavourable position, the AHL control unit will attempt to move this headlight down (using the
stepper motors in the automatic headlight beam throw adjustment).
The AHL control unit is connected to the powertrain CAN.
[more ...]
LM: Light module
> E60, E61, E63, E64, E65, E66 from 03/2005
From 03/2005, the AHL control unit is integrated in the light module.
The light module (LM) controls and monitors all vehicle lights. Information is transmitted and received via
the body controller area network data bus.
The light module actuates the indicator light for the adaptive headlights (on the light switch).
[more ...]
FRM: Footwell module
> E70, E71, E72, E81, E82, E87, E88, E90, E91, E92, E93
The footwell module controls the exterior lights and the adaptive headlights.
The footwell module thus takes the place of the light module and the AHL control unit.
The footwell module controls the indicator light for the adaptive headlights (on the light switch).
[more ...]
The footwell module has its own system description.
[more in the vehicle engineering diagnosis (FTD) 61 04 04 094] ”footwell module”.
The following additional control units are involved in the adaptive headlights:
SMC: Stepper motor controllers
The stepper motor controllers control the stepper motors in the headlights (for the automatic headlight
beam throw adjustment and for the adaptive headlights). The stepper motor controllers are not capable
of self-diagnosis. The stepper motor controllers are diagnosed and encoded via the control unit for
adaptive headlights.
[more ...]
SGM: Safety and gateway module
> E60, E61, E63, E64 until 09/2005 and E65, E66
The safety and gateway module (SGM) is the interface between the two data buses body controller area
network and powertrain CAN. Thus, all messages exchanged between the light module and the AHL
control unit passes through the SGM. Information from the yaw sensor (in the DSC sensor) is also fed
through the SGM to the AHL control unit.
BGM: Body gateway module
> E60, E61, E63, E64 from 09/2005
The vehicle electrical system was changed from 09/2005. As a result of the changeover, several control
units were discontinued and some control unit functions were integrated into new control units.
The new body gateway module (KGM) supersedes the safety and gateway module (SGM) previously
fitted, the door modules and the micro‐power module.
[more in the vehicle engineering diagnosis (FTD) 610205143] ”Body gateway module”
Xenon control unit
The xenon control unit actuates the bulb in the bi-xenon headlights.
The xenon control unit is not capable of self-diagnosis. The Xenon control unit is monitored by the light
module (E70, E71, E72, E81, E82, E87, E88, E89, E90, E91, E92, E93: footwell module).
[more ...]
The following components are controlled:
Headlight
Optional equipment 524 ”Adaptive headlights” is only available in conjunction with optional equipment 522
”Xenon light for dipped and main-beam function”. This means that bi‐xenon headlights are employed.
[more ...]
Stepper motors for the adaptive headlights
The stepper motors turn the swivel modules in the bi‐xenon headlights. The stepper motors move the
headlights vertically and horizontally (vertically = up and down for automatic headlight beam throw
adjustment;horizontally = left and right for the adaptive headlights function).
The swivel modules execute the movement.
[more ...]
Indicator light on the light switch
The indicator light (green light-emitting diode) next to the ”A” (= ”automatic driving lights control” and
”adaptive headlights”) has 2 display functions:
The indicator light lights up permanently when the automatic driving lights control or adaptive
headlights function is switched on (= light switch in position ”A”).
The indicator light flashes if a fault develops in the adaptive headlight system.
> E60, E61, E63, E64, E65 and E66:
The indicator light is activated by the light module.
> E70, E71, E72, E81, E82, E87, E88, E89, E90, E91, E92, E93:
The indicator light is activated by the footwell module.
Note: From 09/2007, the fault display in the form of the indicator light on the light switch flashing is discontinued.
From 09/2007, the fault display in the form of the indicator light on the light switch flashing is
discontinued due to legal stipulations.
From 09/2007 system fault will be indicated by a Check Control message in the instrument panel.
System functions
The adaptive headlights system moves headlights horizontal (i.e. from left to right) in order to illuminate the
inside of a bend when cornering.
The following system functions of the adaptive headlights system are described below:
System activation and reference run
Activation of stepper motor controllers
Speed-dependent evaluation of signals
Adjustment of headlight horizontal aim
Deactivation of adaptive headlights function under extreme driving conditions
Deactivation of adaptive headlights function in response to system faults
Setting headlights to parked position
Automatic headlight beam throw adjustment
Adaptive headlights for automatic driving lights control
Cornering light
Adaptive headlight beam throw adjustment
Variable light distribution (depending on the national-market version)
Note: Different control units for adaptive headlights.
> E60, E61, E63, E64, E65, E66 up to 03/2005: The adaptive headlights are actuated by the AHL
control unit.
> E60, E61, E63, E64, E65, E66 up to 03/2005: The adaptive headlights are actuated by the light
module (LM).
> E70, E71, E72, E81, E82, E87, E88, E89, E90, E91, E92, E93: The adaptive headlights are
controlled by the footwell module (FRM). The footwell module has its own system description.
[more in the vehicle engineering diagnosis (SBT) 61 04 04 094]
For this reason, the following text refers to the general ”control unit for adaptive headlights”.
System activation and reference run
When terminal 15 is switched ON, the headlights always perform a reference run, even if the low-beam
headlights are not switched on. The control unit for adaptive headlights transmits the ”perform reference run”
request to the stepper motor controllers (SMCs, control units for the headlight stepper motors). The
stepper motor controllers control the stepper motors in the headlights. The reference run is performed. In
the reference run, the headlights move as follows:
1. The headlights move to the right and left (= reference run for adaptive headlights).
2. The headlights move up and down (= reference run for automatic headlight beam throw adjustment).
3. At the end of the reference run, the headlights are in the straight-ahead position.
Following the reference run, the system is operational.
Note: The reference run is only performed after terminal 15 has been switched OFF for at least 15 seconds.
> E66, E61, E63, E64, E65, E66 until 09/2006
> E87, E90, E91, E92, E93 until 03/2007
If terminal 15 is repeatedly switched on and off (e.g. for demonstration purposes), the reference
run will not be executed every time terminal 15 is switched on. Terminal 15 must have been
switched off for at least 15 seconds before it is switched on again. Only then is a reference run
performed when terminal 15 is switched on.
Note: Reference run always after terminal 15 ON and low-beam headlights ON.
> E66, E61, E63, E64, E65, E66 from 09/2006
> E70, E81, E82, E88, E89, from series launch
> E87, E90, E91, E92, E93 from 03/2007
If terminal 15 is repeatedly switched on and off (e.g. for demonstration purposes), the reference
run will not be executed every time terminal 15 and the low-beam headlights are switched ON.
Note: Reference run with enlarged movement range.
> not E65, E66
From 09/2007, starting with the E60, E61, E63, E64, a reference run with larger movement range
will be introduced. The reference run with larger movement range will then gradually be introduced
on other model series.
The control unit for adaptive headlights transmits the stepper motor controllers (SMC) the setpoint values
for the swivel modules (position of swivel modules and speed of movement).
The control unit for adaptive headlights calculates the setpoint values using the following signals:
Driving speed
Steering angle (at speeds up to 50 km/h, dependent on encoding)
Yaw rate (50 km/h upwards, see ”Steering angle sensor and DSC sensor” above)
Speed-dependent evaluation of signals

Depending on the driving speed, the adaptive headlights are controlled using the following signals: Signals
from the steering angle sensor and signals from yaw sensor (in the DSC sensor).
The encoding (at the end of line) determines the priority assigned to sensor signals above which speed
threshold.

The stepper motor controllers move the headlights to the right or left during cornering.
Horizontal movement range of headlights:
Inwards, i.e. towards centre of vehicle: up to max. 8°
Outwards: up to max. 15°
Example: Right-hand bend: The right-hand headlight turns by up to 15° (the right-hand headlight is the
”inside” headlight on a right-hand bend).
Viewed from the vehicle, the right-hand headlight moves ”outwards”.
The left-hand headlight moves up to 8° (the left-hand headlight moves towards the centre of the vehicle, i.e.
”inwards” as viewed from the vehicle).
The headlight on the outside of the bend has to reach its end position at the same time as the headlight on
the inside of the bend so that the carriageway remains smoothly and evenly illuminated.
On a right-hand bend, the left-hand headlight is on the outside of the bend. The right-hand headlight is on
the inside of the bend.
Deactivation of adaptive headlights function under extreme driving conditions

If the vehicle drifts, skids and loses sideways grip, the adaptive headlights function is deactivated as
follows:
The headlights are returned to the straight-ahead position. The headlights are no longer turned.
The low-beam headlights remain on.
Until 09/2007, a system fault will be indicated by the indicator light on the light switch flashing.
From 09/2007 system fault will be indicated by a Check Control message in the instrument panel.
Dazzling of oncoming traffic must be prevented in the event of a system fault.
For this reason, the adaptive headlights function is deactivated as follows:
If the stepper motors are still functional, the headlights are returned to the straight-ahead position. The
headlights are no longer moved towards bends in the road.
If it is no longer possible for a headlight to be moved back to the straight-ahead position, the headlight
is lowered (by the stepper motors for automatic headlight beam throw adjustment). This prevents
dazzling of oncoming traffic.
Vehicles up to 09/2007: If the headlight cannot be lowered, the bi-xenon bulb in this headlight is
disabled as follows:
When the vehicle is parked up, the control unit registers rest state for the adaptive headlights, as
follows: Vehicle standstill and terminal R OFF for several minutes.
The next time the vehicle is restarted, the bi-xenon light of the defective headlight is not switched on.
The front fog lights are switched on in order to ensure a minimum level of lighting.
The low-beam headlights are not switched off while the vehicle is in motion.
Note: From 09/2007, the low-beam headlights will not be switched off in the event of a system fault.
If a system fault develops in the adaptive headlights, the low-beam headlights for the affected
headlight will not be switched off.
When terminal R is switched off, the headlights move to the parked position. The parked position is
important for the headlights' next reference run: From the parked position, the headlights are run through a
reference run in the pre-drive check. During each reference run, the control unit for adaptive headlights
relearns the straight-ahead position for the headlights.
When the headlights have reached the parked position, the stepper motor controllers SMCs inform the
control unit for adaptive headlights (”confirmation”).
The control unit for adaptive headlights deactivates the stepper motor controllers.
The after-running period lasts approx. 10 seconds.
Automatic headlight beam throw adjustment
If the optional equipment ”Adaptive headlights” is fitted, the control unit for adaptive headlights also controls
the automatic headlight beam throw adjustment.
The automatic headlight beam throw adjustment adapts the headlight range for different vehicle inclinations.
Variations in the vehicle inclination angle are produced by vehicle loads and braking or acceleration in
extreme driving situations. The automatic headlight beam throw adjustment moves the headlights up and
down as required.
The control unit for adaptive headlights also controls the automatic headlight beam throw adjustment as
follows:
1. The ride height sensors and the brake light switch supply the signals for the automatic headlight beam
throw adjustment.
2. The control unit for adaptive headlights computes the vehicle inclination (longitudinally to the
roadway) from the signals.
3. The stepper motors for the automatic headlight beam throw adjustment automatically and dynamically
control the headlight beam throw.
The headlight range is adjusted so that the actual headlight beam throw conforms to the legally
required headlight beam throw as follows:
If vehicle rear is lower than front: The actual headlight beam throw will be longer than the legally
stipulated headlight beam throw. The headlight beam throw is lowered to reduce the headlight
beam throw to match the legal requirement.
If the vehicle is horizontal: The actual headlight beam throw will be the same as the legally
stipulated headlight beam throw .
If vehicle front is lower than rear: The actual headlight beam throw will be shorter than the legally
stipulated headlight beam throw. The headlight beam throw is raised to increase the headlight
beam throw to match the legal requirement.
The automatic driving lights control feature (optional equipment in conjunction with the rain/light sensor)
automatically switches the side lights and low-beam headlights on or off.
Switch-on conditions:
The automatic driving lights control must be encoded (in the light module on the E60, E61, E63, E64,
E65, E66 , in the footwell module on the E70, E71, E72, E81, E82, E87, E88, E89, E90, E91, E92, E93).
The light switch position must be ”A” (”A” for automatic driving lights control and adaptive headlights).
The rain/light sensor must be installed and operational.
The rain/light sensor detects the ambient brightness.
The rain/light sensor transmits the following requests to the light module (on the E70, E71, E72, E81,
E82, E87, E88, E89, E90, E91, E92, E93: footwell module):
Ambient brightness low: In twilight, darkness, in an underground garage or tunnel.
”Switch on low-beam headlights” request
Ambient brightness sufficient.
”Switch off low-beam headlights” request
If only the side lights are to be switched on, the light switch must be set to side lights (switch position 1).
When the light switch position is set to ”A”, the control unit for adaptive headlights is also activated:
When the automatic driving lights control function switches on the low-beam headlights (e.g. at
dawn/dusk), the adaptive headlights function is notified at the same time.
The control unit for adaptive headlights thus assumes control of the automatic headlight beam throw
adjustment.
The signals from the rain/light sensor are also evaluated (E60, E61, E63, E64, E65, E66: by the light
module; E81, E82, E87, E88, E90, E91, E92, E93: by the footwell module).
The headlights are not turned when the vehicle is cornering until total darkness sets in.
The message ”low-beam headlights on” is given individually for each headlight.
If a headlight fails, the adaptive headlights are switched off. The front fog lights are switched on in order to
ensure a minimum level of lighting.
Cornering light
The cornering light is linked to the adaptive headlight (optional equipment 524).
The footwell module (FRM) uses the following signals to adjust the cornering light:
Steering angle
Yaw rate
Status, reverse gear
> E81, E82, E88, E89, E92, E93 with the series launch and E87 from 03/2007
Instead of the high-beam headlight (H7), the headlight with cornering light has a fixed additional reflector
with an H3 bulb. The special styling of the headlight lens prevents dazzle to the front.
The graphic shows the main headlight with cornering light on

the E81, E82, E87, E88, E89, E92, E93
1) Bi‐xenon lamp
2) H8 bulb for side lights and daytime driving lights
3) H3 bulb for cornering lights
4) Reflector for cornering light
The graphic shows the headlight with cornering light on the E81,
E82, E87, E88, E89, E90, E91, E92, E93
1) Turning left
2) Turning right
The following prerequisites must be satisfied for the cornering lights to be switched on:
Terminal 15 ON
Light switch in position ”A” (”A” stands for automatic driving lights control)
Rain/light sensor identifies twilight or darkness (threshold value exceeded)
At driving speeds greater than 70 kph, the cornering light is no longer switched on.
> European version: For legal reasons, the cornering lights on the European version can only be activated
via the turn indicator at speeds up to 40 km/h.
When reversing, the footwell module (FRM) activates the cornering lights as follows in the speed range
0 km/h to 35 km/h:
US version, both sides
Other countries, only outer side of bend
When the turn indicator is switched on: If the vehicle is stationary, the turning lights will automatically be
deactivated after approx. 4 seconds, e.g. when waiting at traffic lights. However, the turning lights can be
activated again with the turn signal/high beam switch (up to 3 times) until the reflector has reached a certain
temperature. A temperature model protects the headlights against excessive thermal load.
The switching-off conditions for the cornering light depend on the country concerned.
Note: Temperature monitoring by temperature model!
A temperature model in the footwell module calculates the temperature of the reflector. The
temperature at the reflector must not exceed a certain value. If a critical temperature is reached,
the footwell module (FRM) will deactivate the cornering lights. After a cooling-down period, the
cornering light can be switched on again.
> E70; E71, E72 with series launch
The cornering lights are implemented with the front fog lights. (Reason: The installation position of the
headlights is too high for the cornering lights. This prevents legal specifications from being adhered to.)
Depending on activation, the right-hand and/or left-hand front fog light is switched on. The cornering
lights are activated by the light module (LM).
The front fog lights have an additional reflector to improve illumination of the areas to the sides.
When turning, the front fog light on the inside of the turn is automatically activated. The additional
reflector for the cornering light reflects the light beam towards the turning area.
The cornering light is not switched on suddenly but rather dimmed in accordance with special time
parameters. Depending on the country concerned, the turning light is switched on when cornering.
The graphic shows the front fog light on the E70
1) Additional reflector for the cornering light

2) Reflector for the front fog lights
3) Bulb
The following prerequisites must be satisfied for the cornering lights to be switched on:
Terminal 15 ON
Rain/light sensor identifies twilight or darkness (threshold value exceeded)
and
Turn indicator ON (not one-touch flashing)
Speed range (forwards travel):
European and Japanese version from 0 km/h to 35 km/h
US version from 0 km/h to 65 km/h
Swivel angle (theoretical):
In stationary mode ≥ 77°
While driving ≥ 10°
or
Speed range (reversing):
0 km/h to 35 km/h
during stationary mode or driving ≥ 70°
If the vehicle is stationary, the cornering lights will automatically be deactivated after a certain time,
e.g. when waiting at traffic lights. However, the cornering lights can be switched on again using the turn
signal/high beam switch
The following prerequisites must be satisfied for the cornering lights to be switched off:
Light switch not in position ”A” (”A” stands for automatic driving lights control)
Rain/light sensor does not identify twilight or darkness (fallen below lower threshold value)
or
Turn indicator OFF
Speed range (forwards travel):
European and Japanese versions ≥ 40 km/h
US version ≥ 70 km/h
In stationary mode 77°
During driving 10°
or
Speed range (reversing): ≥ 40 km/h
Swivel angle (theoretical): when in stationary mode and when driving below a certain value
or
Vehicle skids and swings out.
or
Front fog lights are switched on with the front fog lights switch.
Adaptive headlight beam throw adjustment

The adaptive headlight beam throw adjustment is employed when driving through dips and over crests. In
accordance with a request from the control unit, the headlight driver module activates the swivel module via
the stepper motors and in this way adjusts the headlight beam throw.
When the vehicle passes through a dip, the headlight beam throw is increased. The swivel module is
moved up slightly. The roadway is illuminated a greater distance ahead.
Index Explanation Index Explanation
1 Vehicle without adaptive headlight 2 Vehicle with adaptive headlight beam
beam throw adjustment throw adjustment
When the vehicle passes over a crest, the headlight beam throw is reduced somewhat. The swivel module is
moved down slightly. This reduces dazzling effect of an oncoming vehicle.

1 Vehicle without adaptive headlight 2 Vehicle with adaptive headlight beam
beam throw adjustment throw adjustment
Variable light distribution (depending on the national-market version)
The variable light distribution enables a broader illumination of the roadway ahead of the vehicle. In
accordance with a request from the control unit, the headlight driver module activates the swivel module via
the stepper motors and in this way adjusts the light distribution. The transitions between the individual light
distributions are smooth. In conjunction with the ”Adaptive Headlight” optional equipment, the following
variable light distribution are available:
Engine start
In switch position “A” (light switch in the switch position for automatic driving lights control) and
terminal 15 ON, both headlights execute a reference run. That means: Both swivel modules are moved
down slightly and then to the desired position (visible when the vehicle is parked in front of a wall: The
light cone moves down and then back up). The desired position depends on the load status of the
vehicle.
When the engine is started, the headlight driver module initially controls the city light distribution.
City light distribution
The city light distribution enables a broader illumination of the left roadway at low speeds. The link
headlight is moved approx. 12° to the left and approx. 0.7° downwards. The city light distribution is
activated from engine start to a driving speed of approx. 50 km/h.
Country road light distribution
The country road light distribution is the same as the standard low-beam headlights. At a driving speed
above approx. 50 km/h, the city light distribution is changed to the country road light distribution. Below
a driving speed of approx. 50 km/h, the footwell module (FRM) changes the light distribution back to
city. The country road light distribution represents the basic setting for the headlights. The basic
setting is assumed when there are faults in the complete light distribution system.
Motorway light distribution
The motorway light distribution increases the range of the driving light. The left headlight is moved
approx. 3.5° to the left and approx. 0.25° downwards. The right headlight is moved approx. 0.2° upward.
If the vehicle speed exceeds 110 km/h for longer than 30 seconds, or if 140 km/h is exceeded, the
footwell module switches on the motorway light distribution. If the vehicle speed drops below 110 km/h,
the headlights are gradually reset, depending on the driving speed. This takes places in stages
(110 km/h - 100 km/h - 90 km/h - 80 km/h). The country road light distribution is activated again at
80 km/h and below.
Fog light distribution
The fog light distribution is activated when the fog lights are switched on. The fog light distribution can
be combined with the city light distribution and the country road light distribution. The link headlight is
moved approx. 8° to the left and approx. 0.7° downwards. If the high beam headlights are switched on
while the fog light distribution is active, the headlight moves to the basic setting, i.e. to the country road
light distribution.
1 City light distribution 2 Fog light distribution
3 Country road light distribution (also the 4 Motorway light distribution

basic setting of the headlights)
Switch-on conditions
The control unit for adaptive headlights is ”awake” from terminal 15 ON. The movement of the lights is subject
to the following preconditions:
Reverse gear must not be engaged.
The system is trouble-free (indicator light not flashing and no Check Control message)
The bulbs for the bi-xenon headlights are OK in both headlights.
The vehicle must not be skidding or fishtailing.
The rain/light sensor must identify darkness.
Additional switch-on conditions: automatic driving lights control is active (light switch position ”A”, see
above).
Warning! Exercise caution when working on bi-xenon headlights
Whenever checking or working on the headlights, always observe the safety regulations and accident
prevention regulations. The headlight system has dangerously high voltage.
Car & Key Memory:
> E60, E61, E63, E64, E65, E66
The sensitivity of the driving light sensor can be set to one of 2 stages with the Car & Key Memory.
> E70, E71, E72, E81, E82, E87, E88, E89, E90, E91, E92, E93
All Car & Key Memory functions are programmed inside the vehicle itself.
(Please refer to the ”Personal profile” section of the Owner's Handbook: Personal profile for a maximum of
3 infrared remote keys via the display in the instrument panel or via the Central Information Display.)
National-market version
The options ”Daytime driving lights” and ”Manual headlight beam throw adjustment” are available in certain
countries. Vehicles with manual headlight beam throw adjustment do not have adaptive headlights. This is
because vehicles with manual headlight beam throw adjustment have low-beam halogen headlights.
Adaptive headlights (optional equipment 524) are only available in conjunction with optional equipment 522
”Xenon light for dipped and main-beam headlights”.
Switching on adaptive headlights in conjunction with daytime driving lights function
The optional equipment ”daytime driving lights” (Northern Europe and Canada) means that
Low-beam headlights and side lights (E70, E92, E93: daytime driving lights) are always switched on:
Light switch in position ”2”
Terminal 15 ON
The automatic headlight beam throw adjustment is active (actuated by the control
unit for adaptive headlights).
If terminal 15 is switched off, the low-beam headlights and the side lights are automatically switched off as
well.
The light switch must also be set to position ”A” with the optional equipment ”Daytime driving lights”. The
control unit for adaptive headlights is then in standby.
System functions for optional equipment ”Daytime driving lights” when the light switch is set to position ”A”:
If the vehicle is encoded with the optional equipment ”Daytime driving lights” (end of line), the light
switch can remain in position ”A” at all times.
When terminal R is switched on, the side lights, parking lights and number-plate lights are switched on.
As soon as terminal 15 is switched on, the low-beam headlights are also switched on.
When the low-beam headlights are switched on, the control unit for adaptive headlights is activated
(for automatic headlight beam throw adjustment).
The indicator light on the light switch lights up and indicates the system’s operational readiness.
The adaptive headlights turn when the vehicle is stationary if the steering-wheel angle is turned (to the
right only).
The headlights are moved during cornering if the rain/light sensor identifies darkness.
The switch-on conditions for the adaptive headlights in conjunction with optional equipment ”Daytime driving
lights” are as follows:
The vehicle must be encoded with the optional equipment ”Daytime driving lights” (end of line)
The light switch must be in position ”A”
Terminal 15 must be switched on and reverse gear must not be engaged
Rain/light sensor must identify darkness
We can assume no liability for printing errors or inaccuracies in this document and reserve the right to
introduce technical modifications at any time.
63 03 03 (047)
Adaptive headlights
E46/2, E46/C, E53, E83
Launch dates for option 524 ”Adaptive headlights”:

E46 Coupé (E46/2) and E46 Convertible (E46/C) model revision: 03/2003
E53: 04/2004 onwards
E83: From 10/2003
Note: Option 524 is only available in conjunction with option 522.
Option 524 ”Adaptive headlights” is only available in conjunction with option 522 ”Xenon dipped
and main-beam headlights”.
Note: ALC = AHL
The development code for the adaptive headlights was ”ALC”.
ALC stood for ”Adaptive Light Control”.
The marketing and sales designation for option 524 in English-language markets is
”adaptive headlights”, abbreviated to ”AHL”.
This is why the abbreviation ”AHL” is used even in diagnosis and technical vehicle documentation.
However, some control units may still bear the abbreviation ”ALC”, which may also be the
abbreviation used in the EPC (Electronic Parts Catalogue).
Introduction
The adaptive headlights turn the bi-xenon headlights towards the inside of a bend when cornering. This
improves illumination of the curve of the road.
Visibility is therefore improved.
When cornering, the driver is not looking into a ”black hole” - instead, the adaptive headlights allow the driver to
see the curve of the road.
> E46/2, E46/C, E53 and
E83 until 09/2006 [system overview ...]
> E83 from 09/2006
[system overview]
Note: AHL control unit discontinued from 09/2006.
On the E83 from 09/2006, the software for the AHL control unit is integrated into the light module
(LM). The AHL control unit is no longer fitted.
The turning lights function is new on the E83 from 09/2006.
The turning lights give the area next to the carriageway additional illumination when you are turning or
cornering (driving in tight bends). The function is also active when you are parking.
The turning lights are realised using the front foglights. The front foglights have a specially shaped reflector
to illuminate the areas to the sides better.
Note: Turning lights only in conjunction with option 524.

Turning lights are a subfunction of option 524 ”Adaptive headlights”.
The following components and control units provide input signals for the adaptive headlights system:
Light switch
The rotary switch for the side lights and dipped headlights differs depending on the vehicle equipment
level (adaptive headlights, automatic driving lights control, automatic or manual headlight-range
adjustment). For the adaptive headlights function to operate, the light switch must be set to position ”A”
(”A” = ”automatic driving lights control” or ”adaptive headlights”).
[more ...]
Turn-signal/main-beam switch
The main-beam headlights are switched on and off with the direction indicator / main-beam switch (by
pressing or pulling the switch). The adaptive headlights function operates with both dipped and main-
beam headlights.
Ride-height sensors
If the special equipment ”Adaptive headlights” is fitted, the adaptive headlights control unit evaluates the
signals from the ride-height sensors.
This is because: the adaptive headlights control unit also controls the automatic headlight-range
adjustment.
The automatic headlight-range adjustment feature adjusts the vertical aim of the headlights to
compensate for variations in the vehicle tilt angle (e.g. when the vehicle is laden, and under braking and
acceleration in dynamic driving situations).
[more ...]
Brake light switch
If the vehicle is equipped with the ”adaptive headlights” option, the signals from the brake light switch are
read by the control unit for the adaptive headlights.
The signal sent by the brake light switch is an input signal for the automatic headlight-range adjustment;
see above: Ride-height sensors.
Zero-position sensor
> E46/2, E46/C
> E83
The zero-position sensor in the AHL headlight sends a signal for calculating the zero position of the AHL
headlight. This regulates the horizontal movement of the AHL headlight.
[more ...]
Position sensor
> E53
The position sensor in the positioner module for the bi-xenon headlights supplies a signal for the
horizontal movement of the headlights.
[more ...]
General module
The basic module supplies input signals with regard to the terminal management (terminal 15 ON).
The adaptive headlights control unit is activated when terminal 15 is switched ON.
EGS control unit or reversing light switch
On vehicles with automatic transmission, the EGS control unit (electronic transmission control) provides
the ”Reverse gear engaged” signal.
On vehicles with manual transmission, the signal is supplied by the reversing light switch.
KOMBI: Instrument cluster
The instrument cluster is the gateway, i.e. the data interface) between the PT-CAN data bus and the K-
bus.
RLS: Rain-light sensor for automatic driving lights control
The rain-light sensor measures the ambient brightness outside the vehicle.
In twilight conditions, the rain-light sensor transmits the message ”Twilight” so that the
automatic headlight-range adjustment can activate dipped headlights. The headlights are tilted up
and down as required, but they are not swivelled towards the bend in the road.
In darkness, the rain-light sensor sends the message ”Darkness”. The adaptive headlights are then
activated when the vehicle is cornering. The headlights are moved to the left or the right:
[more ...]
Steering-angle sensor and DSC sensor
The steering angle sensor and DSC sensor (DSC = Dynamic Stability Control) supply signals for the
adaptive headlights to the adaptive headlights control unit. These signals are evaluated as follows,
depending on the vehicle's speed:
Vehicle speeds up to 30 km/h:
The adaptive headlights function is controlled using the information from the steering angle sensor
(in the steering column switch cluster).
Vehicle speeds between 30 km/h and 50 km/h:
In the 30 to 50 km/h speed range, there is a continuous transition in signal evaluation: from the
evaluation of signals sent by the steering angle sensor to evaluation of the signals sent by the yaw-
rate sensor (in the DSC sensor).
In extreme dynamic driving situations, e.g. if the vehicle starts to skid or fishtail, even at speeds
less than 50 km/h, the signals from the yaw-rate-sensor are considered.
If the vehicle starts to skid or fishtail, the headlights will move to the straight-ahead position. The
headlights are not moved until the vehicle has stabilised.
Vehicle speeds over 50 km/h:
At speeds upwards of 50 km/h, the signals from the yaw-rate sensor (in the DSC sensor) form the
primary basis for control of the adaptive headlights function.
Reason: For a constant cornering radius, the steering angle required increases disproportionately
with speed. In addition, the steering angle required also depends on the coefficient of friction of the
road surface.
The yaw rate is directly proportional to speed. For this reason, the yaw rate is always the most
suitable measure for controlling the adaptive headlights at high speeds.
Even at high speeds, however, the steering angle sensor signal is used to detect (predict) the
driver's commands in advance. This prediction is important: The yaw rate signal is not supplied until
the vehicle has responded to the steering wheel movement.
The steering-angle sensor signal is disabled so that rapid, momentary steering adjustments do not
affect the adaptive headlights function.
A number of control units are involved in the adaptive headlights system (see above: GM, EGS, KOMBI).
Depending on the series and model concerned, the adaptive headlights are actuated by the following control
units:
AHL control unit
> E46/2, E46/C, E53 and E83 until 09/2006
The AHL control unit controls the adaptive headlights.
For safety reasons, the AHL control unit is also responsible for the automatic headlight-range
adjustment. This is because: Oncoming traffic must not be dazzled by the adaptive headlights. If a
headlight sticks in an unfavourable position, the AHL control unit will attempt to move this headlight down
(using the stepper motors in the automatic headlight-range adjustment).
The AHL control unit is connected to the K-bus and the PT-CAN.
[more ...]
LM: Light module
> E83 from 09/2006
The AHL control unit is integrated in the light module.
The light module controls and monitors all vehicle lights. Information is received and transmitted over the
data buses PT-CAN, LIN bus and K-bus.
[more ...]
Stepper motor controllers
The stepper motor controllers (SMC) control the stepper motors in the headlights (for the automatic
headlight-range adjustment and for the adaptive headlights).
[more ...]
LSZ: Light switch cluster
> E46/2, E46/C, E53 and E83 until 09/2006 (E53: light module)
The light switch cluster forwards the prompts from the light switch and from the turn-signal/main-beam
switch to the AHL control unit (via the K-bus).
[more ...]
Xenon-headlight control unit
The xenon-headlight control unit actuates the bulb in the bi-xenon headlights.
[more ...]
The following components are controlled:
Stepper motors for the adaptive headlights
The stepper motors turn the positioner modules in the bi-xenon headlights.
The stepper motors swivel the headlights along the vertical and horizontal axes. (vertical = up and down
for the automatic headlight-range adjustment;
horizontal = to the left and right for the adaptive headlights).
The positioner modules execute the movement.
[more ...]
Indicator light on the light switch
The indicator light (green LED) next to the ”A” (= ”automatic driving lights control”) is actuated by the
adaptive headlights and has 2 display functions:·
The indicator light lights up permanently when the automatic driving lights control or adaptive
headlights function is switched on (= light switch in position ”A”).
The indicator light flashes if a fault develops in the adaptive headlight system.
The indicator light thus supports diagnosis of the adaptive headlights.
The indicator light is actuated by the light switch cluster or by the light module.
System functions
The adaptive headlights system moves headlights horizontal (i.e. from left to right) in order to illuminate the
inside of a bend when cornering.
The following functions of the adaptive headlights system are described below:
System activation and automatic calibration
Speed-dependent analysis of signals
Deactivation of adaptive headlights function under extreme handling conditions
Automatic headlight-range adjustment
Turning light
Note: Different control units for adaptive headlights.
> E46/2, E46/C, E53 and E83 until 09/2006: AHL control unit
> E83 from 09/2006: The adaptive headlights are actuated by the light module.
For this reason, the following text refers to the general ”control unit for adaptive headlights”.
System activation and automatic calibration
When terminal 15 is switched ON, the headlights always perform a calibration sequence, even if the dipped
headlights are not switched on. The control unit for adaptive headlights (AHL control unit or light module)
sends the ”perform calibration sequence” prompt to the stepper motor controllers (SMCs, control unit for
the headlight stepper motors). The stepper motor controllers actuate the stepper motors in the headlights.
The calibration sequence is performed.
In the calibration sequence, the headlights move as follows:

The headlights move to the right and the left (= calibration sequence for adaptive headlights).
The headlights move up and down (= calibration sequence for automatic headlight-range adjustment).
At the end of the calibration sequence, the headlights are in the straight-ahead position.
Following the calibration sequence, the system is ready for operation.
Note: The calibration sequence is performed only after terminal 15 has been switched OFF for at least
15 seconds.
If terminal 15 is repeatedly switched on and off (e.g.for demonstration purposes), the calibration
sequence will not be executed every time terminal 15 is switched on. Terminal 15 must have
been switched off for at least 15 seconds before it is switched on again. Only then is a calibration
sequence performed when terminal 15 is switched on.
The control unit·for·adaptive·headlights (AHL control unit or light module) sends the stepper motor
controllers (SMC) the nominal values for the positioner modules (position of positioner modules and speed
of movement).
The control unit for adaptive headlights calculates the nominal values using the following signals:
Vehicle road speed
Steering angle (at speeds up to 50 km/h, dependent on encoding)
Yaw rate (50 km/h upwards, see ”Steering-angle sensor and DSC sensor” above)
Speed-dependent analysis of signals

The adaptive headlights are controlled by the following signals depending on the road speed: signals from
the steering angle sensor or signals from yaw-rate sensor (in the DSC sensor). The encoding (at the end of
the production line) determines the priority assigned to sensor signals above which speed threshold (see
above).
The stepper motor controllers move the headlights to the right or left when the vehicle corners.
Horizontal range of movement of headlights:
Inwards, i.e. towards centre of vehicle: up to max. 8°
> E46/2, E46/C, E83: 7°
> E53: 8°
Outwards: up to max. 15°
Example: Right-hand bend:
The right-hand headlight turns by up to 15° (the right-hand headlight is the ”inside” headlight on a right-hand
bend).
It therefore swivels outwards away from the vehicle centre.
The left-hand headlight swivels through a maximum of 8° (the left-hand headlight swivels towards the
vehicle centre, i.e. inwards).
The headlight on the outside of the bend reaches its end position at the same time as the headlight on the
inside of the bend, ensuring that the road is evenly illuminated.
On a right-hand bend, the left-hand headlight is on the outside of the bend. The right-hand headlight is on
the inside of the bend.
Deactivation of adaptive headlights function under extreme handling conditions

If the vehicle drifts, skids and loses sideways grip, the adaptive headlights function is deactivated as
follows:
The headlights are returned to the straight-ahead position. The headlights are no longer turned.
The dipped headlights remain on.

In the event of a system error, the indicator light on the light switch will flash.
Dazzling of oncoming traffic must be prevented in the event of a system fault.
For this reason, the adaptive headlights function is deactivated as follows:
If the stepper motors are still functional, the headlights are returned to the straight-ahead position. The
headlights are no longer moved towards bends in the road.
If it is no longer possible for a headlight to be moved back to the straight-ahead position, the headlight
is tilted downwards (by the stepped motors for automatic headlight-range adjustment). This prevents
dazzling of oncoming traffic.
If the headlight cannot be tilted downwards, the bi-xenon bulb in this headlight is disabled as follows:
When the vehicle is parked up, the control unit registers sleep mode for the adaptive headlights, as
follows: Standstill and terminal R OFF for several minutes.
The next time the vehicle is restarted, the bi-xenon light of the defective headlight is not switched on.
The front foglights are switched on in order to ensure a minimum level of illumination.
The dipped headlight is not switched off while the vehicle is in motion.

When terminal R is switched off, the headlights move to the parked position. The parked position is
important for the headlights' next calibration sequence. From the parked position, the headlights are run
through a calibration sequence in the pre-drive-check. During the calibration sequence, the control unit for
adaptive headlights relearns the straight-ahead position for the headlights.
When the headlights have reached the parked position, the stepper motor controllers SMCs inform the
control unit for adaptive headlights (”verification”).
The control unit for adaptive headlights deactivates the stepper motor controllers. The run-down period
lasts approx. 10 seconds.
Automatic headlight-range adjustment
If the special equipment ”Adaptive headlights” is fitted, the control unit for adaptive headlights also controls
the automatic headlight-range adjustment.
The automatic headlight-range adjustment adapts the headlight range for different operating conditions.
Variations in the vehicle tilt angle are produced by vehicle loads and braking or acceleration in extreme
driving situations. The automatic headlight-range adjustment moves the headlights up and down as
required.
The control unit for adaptive headlights also controls the automatic headlight-range adjustment as follows.
1. The ride-height sensors and the brake light switch supply the signals for the automatic headlight-range
adjustment.
2. The control unit for adaptive headlights computes the vehicle inclination (longitudinally to the
roadway) from the signals.
3. The stepper motors for the automatic headlight-range adjustment automatically and dynamically
control the headlight range.
The headlight range is adjusted so that the actual headlight range conforms to the legally required
headlight range as follows:
If vehicle rear is lower than front:
The actual headlight range will be longer than the legally stipulated range. The headlight beam
height is lowered to reduce the headlight range to match the legal requirement.
If the vehicle is horizontal:
The actual headlight range will be the same as the legally stipulated range.
If vehicle front is lower than rear:
The actual headlight range will be shorter than the legally stipulated range. The headlight beam
height is raised to increase the headlight range to match the legal requirement.
The automatic driving lights control feature (option in conjunction with the rain-light sensor) switches the
side lights and dipped headlights on and off automatically.
Switch-on conditions:
The automatic driving lights control must be encoded in the light switch cluster or light module.
The light switch must be in position A” (”A” stands for automatic driving lights control and for
adaptive headlights).
The rain-light sensor must be installed and operational.
The rain-light sensor detects the brightness of the ambient light.
The rain-light sensor sends the following prompts to the light switch cluster or the light module:
Ambient brightness low: In twilight, darkness, in an underground garage or tunnel.
”Switch on dipped headlights” request
Ambient brightness sufficient.
”Switch off dipped headlights” request
If only the side lights are to be switched on, the light switch must be set to side lights (switch position 1).
When the light switch is set to position ”A”, the control unit for adaptive headlights is also activated:
When the automatic driving lights control function switches on the dipped headlights (e.g. at twilight),
the adaptive headlights function is notified at the same time.
The control unit for adaptive headlights then assumes control of the automatic headlight-range
adjustment.
In addition, the signals from the rain-light sensor are also evaluated. The headlights are not turned
when the vehicle is cornering until total darkness sets in.
The message ”dipped headlights on” is given individually for each headlight.
If a headlight fails, the adaptive headlights are switched off.
The front foglights are switched on in order to ensure a minimum level of illumination.
Turning lights
> E83 from 09/2006
The turning lights are coupled to the adaptive headlights (option 524).
Depending on actuation, the right-hand and/or left-hand front foglight is switched on. The turning lights are
actuated by the light module (LM). The turning light are not switched on suddenly but rather faded according
to special time parameters.
Depending on the country concerned, the turning lights are switched on when cornering.
The following conditions must be satisfied for the turning lights to be switched on:
Terminal 15 ON
Rain-light sensor detects twilight or darkness (threshold exceeded)
and
Turn signal indicator ON (not one-touch turn signal)

Speed range (forwards):
Europe and Japan version from 0 km/h to 35 km/h
US version from 0 km/h to 65 km/h
when stationary ≥ 77°
when driving ≥ 10°
Alternatively
Speed range (reverse):
0 km/h to 35 km/h
when stationary or driving ≥ 70°
If the vehicle is stationary, the turning lights will automatically be deactivated after a certain time, e.g. when
waiting at traffic lights. However, the turning lights can be activated again with the turn-signal/main-beam
switch.
The light module (LM) uses the following signals to actuate the turning lights:
Steering angle
Yaw rate
Status of reverse gear
The following conditions must be satisfied for the turning lights to be switched off:
Light switch not in position ”A” (”A” stands for automatic driving lights control)
Rain-light sensor does not detect twilight or darkness (lower threshold exceeded)
Alternatively
Turn signal indicator OFF
Speed range (forwards):
Europe and Japan versions ≥ 40 km/h
US version ≥ 70 km/h
when stationary 77°
when driving 10°
Alternatively
Speed range (reverse): ≥ 40 km/h
Swivel angle (theoretical): when stationary and when driving below a certain value
Alternatively
Vehicle skids and swings out.
Alternatively
Front foglights are switched on with the front foglights switch.
Preconditions for activation

The control unit for adaptive headlights is ”awake” from terminal 15 ON.
The movement of the lights is subject to the following conditions:
Reverse gear must not be engaged.
No system faults must be present. The indicator light must not be flashing.
The bulbs for the bi-xenon lights are OK in both headlights.
The vehicle must not be skidding or fishtailing.
The rain-light sensor must detect darkness.
Additional precondition for activation: automatic driving lights control is active (light switch in position ”A”,
see above).
Caution: Exercise caution when working on bi-xenon headlights
Whenever inspecting or working on the headlights, always observe the safety precautions and accident
prevention rules. The headlight system has dangerously high voltage.
Car and Key Memory:
The sensitivity of the driving light sensor can be set with the Car and Key Memory.
National versions
The options ”Daytime driving lights” and ”Manual headlight-range adjustment” are available in certain countries.
Vehicles with manual headlight-range adjustment do not have adaptive headlights.
This is because vehicles with manual headlight-range adjustment have halogen dipped headlights;
adaptive headlights are only available in conjunction with option 522 ”Xenon dipped and main-beam
headlights”.
Switching on adaptive headlights in conjunction with daytime driving lights function
The ”Daytime lights” option (Northern Europe and Canada) means that
The dipped headlights and the side lights are always switched on under the following conditions:
Light switch in position ”2”
Terminal 15 ON
The automatic headlight-range adjustment is active (actuated by the control unit for adaptive headlights).
If terminal 15 is switched off, the dipped headlights and the side lights are automatically switched off as well.
The light switch must also be set to position ”A” with the ”Daytime driving lights” option. The control unit for
adaptive headlights is then in standby.
System functions for ”Daytime lights” option when the light switch is set to position ”A”:
If the vehicle is encoded with the ”Daytime driving lights” option (end of production line), the light switch
can remain in position ”A” at all times.
When terminal R is switched on, side lights, parking lights and licence plate lights are switched on.
As soon as terminal 15 is switched on, the dipped headlights are also switched on.
When the dipped headlights are switched on, the adaptive headlights control unit is activated (for
automatic headlight-range adjustment).
The indicator lamp on the light switch lights up and indicates that the system is functional.
The adaptive headlights turn when the vehicle is stationary if the steering wheel is turned (to the right
only).
The headlights are moved when the vehicle corners if the rain-light sensor registers darkness.
The switch-on conditions for the adaptive headlights in conjunction with special equipment ”Daytime driving
lights” are as follows:
The vehicle must be encoded with the ”Daytime driving lights” option (end of production line)
The light switch must be in position ”A”
Terminal 15 must be switched on and reverse gear must not be engaged
Rain-light sensor must detect darkness
Subject to change.
66 01 99 (457)
New master key
All models from 09/99
Table of contents
1 Radio technology
2 Master key, general
3 System overview
4 Functions of the infrared remote control
5 Operational reliability
6 New master key (spare key)
6.1 Operating logic of the input keys
6.2 Signal processing
6.3 Voltage supply
6.4 Voltage monitoring
7 System initialisation
8 Diagnosis
9 System network
be in touch with you at an appropriate time with further details.
1 Radio technology
Radio technology is an umbrella term covering all fields of wireless news communication, e.g. telephone, radio,
television. Transmission is performed by electromagnetic waves.
Due to the fact that radio waves are not directional and have a wider range than infrared waves, this
technology is frequently employed for remote control handsets.
For example, in automotive construction, the same technology is used as for example in remote control
systems for construction cranes, model building, alarm systems, garage door openers etc. These remote
control units are operated at the same approved frequency (315 MHz or 433,92 MHz).
2 Master key, general
The master key for the central locking system (FZV) is a further development of the compact radio master key
or the radio master key first used in the E38.
The master key continues to be located in the key grip of the ignition key, while the receiver module is
installed in the vehicle. All radio signals are encrypted by an alternating code. This prevents the vehicle from
being opened by ”overheard” messages.
Depending on vehicle type and equipment as well as national-market version, alongside the functions of
”central locking system, opening/closing” and ”deadlocking” other functions are also possible: e.g. ”arm/disarm
the alarm system”, ”disable the tilt sensor/interior movement detector”, ”windows and slide/tilt sunroof,
convenient opening/closing”, ”interior light, switch on” and ”tailgate, open/close.
The master keys can be initialised independently of BMW Service points on the vehicle, either if additional
keys are requested or, for safety reasons, following the loss of a master key. The initialisation procedure is
described in each of the operating instructions.
ID transmitters are offered as standard equipment in the E38, E39, E46 model and as optional equipment in the
E36 models (SA 302).
Up to 4 master keys can be operated on one vehicle.
The ID transmitter is subject to the prevailing radio technology legislation in individual countries. The required
identification is located on the key grip.
3 System overview
The ID transmitter consists of:
1 - Transmitter (integrated in the key grip)
2 - Basic module for the central body electrics (ZKE)
3 - Receiver module (integrated in the aerial amplifier or the Diversity aerial)
4 - Aerial in the rear window or side window behind, as in the Touring version (estate car)
Depending on location relative to vehicle, the reception characteristics of radio signals from the transmitter
may vary. The reference point is the rear area (aerial) on the vehicle.
Due to external influences, the range or function of the master key can vary either positively (through
reflections) or negatively as a result of source of interference (technical radio equipment) from the distances
quoted below.
Third party radio equipment / devices operating at the same frequency(433.92 MHz; 315 MHz; 70 cm
waveband) with a higher output power rating can adversely affect the function of the master key. These
sources of interference can include:
- Radio headphones (also known as wireless headphones)
- Radio transceivers (amateur radio; mobile phone; remote-controlled model toys)
- Radio modems
- Garage door opener
- Telemetry transmitter, e.g. weather station with temperature sensor
- House alarm systems with sensors
- Radio remote control charging sockets
- Radio bell (for personal calls)
- TV radio systems (back channel for remote TV viewing)
- Industrial equipment
- Unsuppressed electric motors
4 Functions of infrared remote control
- Central locking system (ZV) open/close
- Switching on the interior lighting
- Arm/disarm anti-theft warning system (DWA)
- Enable/disable tilt sensor and interior movement detector on the DWA
- Open/close side windows
- Open/close sliding sunroof
- Open and close rear lid/tailgate.
- Enable/disable panic mode - only US models When required, this function can be used via the DWA to
trigger an alarm.
5 Operational reliability
From ignition lock position 1 (terminal ”R”), no further control functions are performed by the master key.
If after ”deadlocking” of the central locking system (ZV) the ignition lock is moved into position 1, the ZV
switches from ”deadlocking” to ”central locking”.
If there is a spare key in the ignition lock identified as valid by the electronic immobiliser III, the central locking
system cannot be actuated in ”deadlocking” position.
Due to the high range, ”convenient closing” of the rear hinged windows on the E46 Coupé is not possible
because these windows are not equipped with the anti-trap mechanism.
All convenience functions and the locking of the automatic tailgate only operate while the corresponding
button on the master key is being depressed.
6 New master key (key)
From September 1999 a new generation of master key is entering volume production.
The principal main functions have remained the same since the previously used kind of master key.
The control functions are still actuated by three buttons.
Here are the changes at a glance:

1. New optics with coloured BMW logo.
2. New button configuration and larger buttons.
3. An accumulator instead of a battery which is charged via the ring aerial on the ignition lock.
4. The key housing is watertight and dust-tight, sealed shut and cannot be opened at all.
5. The functional display (red LED) is discontinued.
6.1 Operating logic of the input keys (main functions)
Press button 1 briefly:

- Central locking system closes, goes into deadlocking, when necessary the DWA is enabled.
- Interior light is switched on when vehicle is locked.
- Panic mode (on US versions) will be disabled again.
Button 1 press for a second time at short intervals:
- The interior movement detector and the tilt sensor on the DWA are disabled.
Press and hold down button 1:
- Close central locking system, side windows and slide/tilt sunroof (”convenient closing”). This function is
country-specifically encoded and is not available in all countries.
- Central locking system opens, interior light switches on, if necessary, the DWA is disabled.
- Open central locking system, side windows and slide/tilt sunroof (”convenient opening”).
- Tailgate opens.
- Panic mode (on US version) is enabled.
- Close automatic tailgate.
Individual functions may vary from the ones shown above, depending on the applicable country coding
and the settings made via Car & Key Memory.
6.2 Signal processing
Signal processing is performed by a microcontroller on the printed circuit board in the key housing. This
microcontroller
- evaluates the keystrokes,
- generates a new keycode,
- switches the keycode,
- controls the transmitter stage,
- monitors the power supply (accumulator) on the master key.
1 - EWS transponder 2 - Microswitch for tailgate 3 - Microswitch

”locking” 4 - Quartz crystal for microcontroller 5 - Microswitch
”unlocking” 6 - Microcontroller 7 - Coil aerial
The signals issued by the transmitter output stage are transmitted by the aerial integrated on the printed circuit
board (PCB). The carrier frequency is 433,92 MHz (ECE) or 315 MHz (US), depending on national registration.
During initialisation of the system, a keycode is formed and saved in the microcontroller of the master key.
After every keystroke on the master key, a new keycode is transmitted (alternating code). These code are
calculated further using a defined procedure, ensuring that the receiver module can distinguish reliably
between its own master key and third party master keys.
Note:
Every transmitter can 'lose' its keycode if, for example, someone playfully actuates the buttons during the
initialisation sequence while standing outside the vehicle. In such cases, all the radio stations programmed in
the vehicle will need to be initialised again.
6.3 Voltage supply

No batteries are used in this new master key. Instead, it has a rechargeable vanadium-lithium accumulator.
New master keys are supplied to customers with charged accumulators.
1 - Accumulator 2 - high-frequency aerial (433,92 MHz or 315

MHz)
The accumulator is charged inductively from ignition lock position 1 (terminal ”R”). The charging process is
performed by the ring aerial in the ignition lock and via the coil aerial integrated in the master key. There is an
electronic charger on the printed circuit board which controls the charging process.
The accumulator is designed for a very long service life. The prerequisite for this is that he master key is being
used.
If master keys are not used, the accumulator will discharge completely within about 1.5 years. It takes about 30
hours to fully recharge an accumulator that has completely lost its charge. After approx. 30 minutes 'on
charge', the master key can be used about 15 times.
6.4 Voltage monitoring
Once the end-point voltage has been reached, it may no longer be possible to lock the vehicle centrally using
the master key. Even the ”convenient closing” and the initialisation of master keys is no longer possible.
With every keystroke, the accumulator voltage in the master key is monitored. Since the accumulator
message was delivered in the form of three consecutive 'data telegrams', it is stored for diagnosis purposes in
the basic module of the central body electrical system (ZBE) together with the relevant master key number.
The entry is cancelled if five consecutive 'data telegrams' from the master key fail to include the accumulator
message.
On the E38 and E39 models, this status is already displayed in the form of a message in the Check Control.
7 System initialisation
To enable the master keys to communicate with the vehicle, every single master key must be initialised using
the receiver module. On each vehicle, up to four master keys can be initialised and used.
Since every master key has its own keycode, whenever for example a new master key is added, all existing
master keys need to be initialised once again.
Initialisation procedure :
1. Open the central locking system (ZV) using the ignition key.
2. Get into the vehicle and close all doors.
3. With an ignition key, turn the ignition lock briefly to ignition lock position 1, switching it on and back off
again. It must remain switched on for less than 5 seconds, otherwise the system will not be ready to
initialise.
4. On the master key, press button 2 and hold it down.
5. Press button 1 three times (within 10 seconds). Keep button 2 pressed down.
6. Release button 2.
7. The ZV signals that a master key has been initialised successfully with ”locking” and immediate
”unlocking” messages.
If the acoustic signal from the ZV does not appear, you need to recommence initialisation.
On completion of the first initialisation process, another three master keys can be initialised.
On every additional master key, within 30 seconds with Point 4 (see above), the procedure needs to be
repeated, otherwise initialisation readiness is disabled.
During the initialisation process, all existing master keys need to be initialised. Under no circumstances must
the ignition lock be actuated again during the initialisation process. If this does occur, all master keys need to
be initialised once again.
8 Diagnosis
The master key has diagnostic capability via the DIS and MoDiC below the ”Central Body Electrics - ZKE”.
9 System network
Using the master keys, various functions in the following systems can be enabled or disabled: ZKE, anti-theft
warning system (DWA) and the electronic immobiliser (EWS). During the vehicle diagnosis it is important to
understand the influence of the master key on the overall system.
System network, an exampleE46
Graphics Designation
Z Ignition lock, electromechanical component

EWSIII Electronic immobiliser control unit
EWSIII/1 Output - signal from starter motor (X1659)
EWSIII/3 Input - signal from ignition starter switch (X1659)
EWSIII/4 Output - signal from engine control unit, unidirectional
(X1659)
EWSIII/5 Output - signal from ring aerial (X1659)
EWSIII/6 Input - signal from switch for transmission control unit
(X1659)
EWSIII/9 Earth (X1659)
EWSIII/10 Input - terminal 30 from fuse F67 (X1659)
EWSIII/11 Input - terminal R from ignition lock via fuse F14
(X1659)
EWSIII/12 Output - signal from ring aerial (X1659)
EWSIII/13 Input/output - signal from body bus (X1659)
F9 Fuse, terminal 30/5A
LSZ Lighting switch centre
LSZ/21 Input/output - body bus (X12)
LSZ/31 Earth (X12)
LSZ/47 Output - signal for locator lighting (58g) (X12)
ILV Interior lights, front
AGS Automatic transmission control unit
DME/DDE Digital Motor Electronics/Digital Diesel Electronics
DME/33 Input - enable signal from EWS (X6004)
CAN Controller Area Network (CAN bus)
K-Bus Body bus
FH Power window regulator (symbol for all power window
regulators in the vehicle)
SHDM Slide-tilt sunroof module
SMT Lock module (symbolic for all doors)
HK Rear-lid motor
TK Fuel filler cap drive
USIS Ultrasonic passenger compartment protection
NG Pitch sensor
FZV Radio central locking receiver
FZV/1 Input - signal for terminal 30 from fuse F49 (X1143)
FZV/2 Earth (X1143)
FVZ/3 Input/output - signal from radio transmitter (X1153)
GM Basic module V
GM/3 Output - signal from consumer shutdown (X332)
GM/5 Output - signal from tilt sensor, tilt monitoring (X254)
GM/6 Input - signal from electronic immobiliser, tilt monitoring
(X254)
GM/8 Input - signal from switch for interior light, front,
continuous operation (X253)
GM/8 Output - control signal, emergency power siren, DWA
alarm (x254)
GM/9 Input/output - signal from body bus (X253)

GM/10 Earth (X253)
GM/15 Earth (X253)
GM/17 Output - signal from tailgate motor, unlocking, for drive
on tailgate/rear lid (X253)
GM/18 Input - signal for interior light (X253)
GM/23 Output - signal from alarm system LED (X254)
GM/24 Input - signal for interior movement detector (USIS)
(X254)
GM/27 Input - terminal R from fuse F9 (X253)
GM/35 Output - signal for unlocking the fuel filler flap (X253)
GM/42 Input - signal for tailgate contact from tailgate drive
(X253)
GM/47 Input - signal for terminal 30 from fuse F49 (X253)
GM/49 Input/output - signal from data line for wireless remote
control (X253)
GM/50 Output - signal for locking the fuel filler flap (X253)
TXD Diagnosis bus on the diagnostic connector
84 05 03 (049)
Car telephone Professional
E39, E46, E53, E85
Introduction
With the series E39, E46, E53 and E85 vehicles, the new permanently installed telephone based on the GSM
standard (Global Standard for Mobile Communications) is installed. For the permanently installed telephone,
the global Everest standard was created (not including Japan). The Everest operating system can be used for
all permanently installed telephones with MOST and K-bus connections (MOST = Media Oriented System
Transport, K-bus = body bus).
In the series E39, E46, E53 and E85 vehicles, the Everest platform is installed with a K-bus connection (i.e. a
body bus interface).
The Everest platform is a control unit that can be equipped to suit various national-market versions and for
various requirements. The control unit is designated as a Telematic Control Unit (TCU). [system overview ...]
New features: The Everest platform comprises the following innovations in the EURO national-market version:
Transmitter and receiver for GSM dual band 900/1800 MHz
Standard platform for its functions
Telephone
Telematics (emergency call, breakdown call)
Short Message Service (SMS)
Bluetooth module for communication with a Bluetooth handset
Bluetooth handset for communication with the TCU (Telematic Control Unit)
Shielded privacy mode using Bluetooth handset with Bluetooth connection
Making hands-free calls (using microphone and speaker)
Scope for connecting Bluetooth-capable devices (laptop computer, Personal Digital Assistant = PDA,
etc.) to transmit data via the TCU (Telematic Control Unit) to the GSM network.
At present, it is not possible to operate the TCU by laptop or PDA.
In SA 638 ”Professional car phone” the Telematic Control Unit (TCU) is the transmitter and receiver unit as well
as the control unit. The TCU (Telematic Control Unit) is equipped with a Bluetooth interface which is connected
to a Bluetooth aerial. The TCU and the Bluetooth handset communicate with one another using their Bluetooth
interface and Bluetooth aerials. To communicate with one another, the TCU (Telematic Control Unit) and
Bluetooth handset need to be connected together. The Bluetooth handset is connected to the TCU
(Telematic Control Unit) and communication between Bluetooth handset and TCU takes place based on the
Bluetooth radio/wireless standard. [more ...]
The TCU is the interface between the Bluetooth handset and the components and functions in the vehicle
required for making calls.
With the Bluetooth radio standard, a wireless connection is established automatically in the Bluetooth
reception area between the TCU and the Bluetooth handset. A Bluetooth handset logged onto the TCU is
detected automatically within the Bluetooth reception area. The automatic setting up of a radio link makes it
possible to use the logged in Bluetooth handset in the reception area without manual operation. With
SA 638 ”Professional car phone” it is possible to make hands-free calls (using the hands-free system). Due to
the fact that the wireless link between TCU and Bluetooth handset is established automatically using the
Bluetooth radio standard, once switched on, no further operation is required on any of the following control
devices:
Bluetooth handset
BMW radio, on-board computer, etc.
Legislation permits the driver to use hands-free mode while driving. The SA 638 ”Professional car phone” is
only installed in vehicles with the EURO national-market version.
The Professional car phone comprises the following components:
Telematics Control Unit (TCU)
The TCU is the transmitter and receiver unit for the Professional permanently installed telephone. The
TCU is designed for GSM dual band and the frequencies 900/1800 MHz. The TCU is connected to the
body bus which means it is also connected to the other data bus systems in the vehicle. The TCU also
monitors the state of charge of the accumulator (e.g. lithium-ion battery) in the Bluetooth handset and
controls the charging process. [more ...]
Eject box
The Bluetooth handset is stowed in the eject box in the storage compartment of the centre console. The
eject box contains a SIM card holder for keeping the SIM card safe (SIM = Subscriber Identity Module). In
addition, a SIM card reader and the charger for the accumulator / battery on the Bluetooth handset are
integrated into the eject box. Once the Bluetooth handset is locked into the eject box, the state of
charge of the accumulator (e.g. lithium-ion battery) is monitored in the Bluetooth handset. The
accumulator is charged automatically once the state of charge drops below a defined limit. The eject box
is connected to the Telematic Control Unit (TCU) via a plug connection and the wiring harness. [more ...]
Caution! Lock the Bluetooth handset in the eject box when driving.
This has the following benefits:
Reduced risk of injury from loose objects inside the vehicle in the event of sharp braking.
Continuous checking of state of charge of the accumulator (e.g. lithium-ion battery) and
automatic charging.
Eject box with SIM card holder
The SIM card (Subscriber Identity Module) is installed in the pull-out SIM card holder on the eject box. The
eject box contains a SIM card reader for reading data on the SIM card (e.g. phone numbers and data for a
GSM network). [more ...]
Bluetooth handset
The Bluetooth handset is the mobile operating unit for the Telematic Control Unit (TCU) in the reception
area of Bluetooth. With the Bluetooth handset, e.g. in privacy mode, calls can be made, and text
messages can be sent and received using Short Message Service (SMS). [more ...]
GSM aerial
The GSM aerial is the transmitter/reception aerial for the Telematic Control Unit (TCU), used for
communication with a mobile phone network. The GSM aerial is mounted outside the vehicle. [more ...]
Bluetooth aerial
The Bluetooth aerial is the transmitter/reception aerial for the Telematic Control Unit (TCU), used for
communication with the connected Bluetooth handsets. The Bluetooth aerial is installed inside the
vehicle. [more ...]
The complete function includes:
Radio
The radio directs voice information from the Telematic Control Unit (TCU) to the speakers as an audio
frequency signal (low-frequency [LF] signal). A radio with multi-information display (MID) is used to display
telephone functions:
The addresses stored on the SIM card can be displayed as phone book entries (phone numbers).
A displayed phone number can be selected by the controller. By pressing the controller, a
connection is established with the phone number dialled.
Multifunction steering wheel
The buttons for the telephone functions are located on the multifunction steering wheel (MFL). A call is
accepted or ended by pressing the call button. When accepting a call with the call button, the TCU
switches to hands-free mode.
Hands-free microphone
The hands-free microphone is connected directly to the TCU (Telematic Control Unit). During hands-free
mode, there is no need to operate the Bluetooth handset. With the hands-free microphone, the voice
call is forwarded to the TCU. Making calls with the handset while driving is prohibited by legislation in many
countries.
Caution! When driving, the driver is only permitted to make and receive calls in hands-free mode.
Making calls in hands-free mode (using the microphone and the speakers in the vehicle) is legally
permitted for drivers while the vehicle is in motion.
Speakers
The speakers convert these audio frequency signal (AF signals, voice information from the hands-free
module) of the call into sounds then broadcasts these inside the passenger compartment.
Emergency call button

The emergency call button is shown on the central information display or on the on-board computer in the
telephone menu. The emergency call button is connected to the Telematic Control Unit (TCU). Pressing
the emergency call button initiates a manual emergency call.
System functions
The system functions for making calls with the Telematic Control Unit (TCU) and the connected Bluetooth
handset are based on wireless transmission of information with the Bluetooth radio standard.
Caution! Note country-specific approval governing the use of Bluetooth technology.
Bluetooth technology is not authorised in all countries. In the absence of approval, provisionally
disconnect the Bluetooth connection between the Bluetooth handset and the Telematic Control
Unit (TCU) for the time being spent in that country.
Main functions of the Telematic Control Unit (TCU) for telephone
The TCU permits the following main functions in its basic version:
Hands-free mode
Privacy mode
Hands-free mode
Caution! When driving, the driver is only permitted to make and receive calls in hands-free mode.
Making calls in hands-free mode using the hands-free microphone and the speakers in the
vehicle is legally permitted for drivers while the vehicle is in motion.
Whenever an incoming call is accepted using the call button on the multifunction steering wheel, the system
automatically switches to hands-free mode. If the radio is switched off when the incoming call arrives, the
audio system automatically switches to voice output. The call is conducted in the vehicle using digitised full
duplex transmission via the hands-free microphone and the speakers. The digitisation of analogue voice
signals improves the quality of transmission. Voice calls become easier to understand.
Privacy mode
Caution! When driving, the driver is not permitted to make and receive calls in privacy mode.
Making calls in privacy mode with the Bluetooth handset is only permitted for passengers when a
vehicle is in motion.
In privacy mode, the call is conducted via the Bluetooth handset. Use of the Bluetooth handset makes it
harder for other people to overhear a call. When switching on the privacy mode, the hands-free mode is
switched off.
In the Short Message Service (SMS), incoming SMS messages are displayed on the screen of the
Bluetooth handset or on the multi-information display (MID) of the radio, and/or in the central information
display (CID). An SMS text message can only be written and sent on the Bluetooth handset.
Telematics
The scope of possible uses for telematics is dependent on the installed optional equipment. In vehicles with
the EURO national-market version, the SA 638 ”Professional car phone” is only used in conjunction with
SA 609 ”Navigation system Professional”.
Installation of SA 612 ”BMW Assist” extends the range of possible uses. Once the aforementioned optional
equipment has been installed, the following telematics services can be used:
Manual emergency calls, either via the Bluetooth handset or via the emergency call button
Automatic emergency call
Breakdown call (only with SA 612 ”BMW Assist” with contract)
If the SA 609 ”Navigation system Professional” is not installed, an emergency call can only be made manually
via the Bluetooth handset: Enter the country-specific emergency call number (in Germany, this is 112).
Note: emergency call also possible without SIM card.
An emergency call can always be transmitted, even if no SIM car was detected, or inserted in the
card holder.
Manual emergency call By pressing the emergency call button, a manual emergency call is activated (in
Germany, this involves dialling the country-specific emergency call number 112).
Automatic emergency call: In the event of a relatively serious accident, the Safety and Gateway Module
(SGM) sends a crash message to the Telematic Control Unit (TCU) via the body bus. Then the TCU sets up
a connection with the country-specific emergency call number.
Manual and emergency call with installed SA 612 ”BMW Assist”

Manual emergency call via the emergency call button: After pressing the emergency call button, the
Telematic Control Unit (TCU) first attempts to set up a voice connection with the service provider.
Automatic emergency call: when a crash message is generated, the TCU initiates an emergency call to
the service provider. The service provider attempts to establish a voice connection with the people in
the vehicle to elicit the following items of information:
severity of the accident
number of people injured
condition of the injured persons Rescue services are then alerted on the basis of the information
obtained.
In addition, the TCU accompanies both emergency calls with an SMS text message providing the
location coordinates of the vehicle to the service provider. If it is not possible to establish a
connection, the country-specific emergency call number is dialled.
Breakdown call: A breakdown call is only possible if SA 612 ”BMW Assist” is installed, and only if a contract
has been concluded for the use of the BMW Group Mobile Service. On the on-board computer or on the
central information display (CID) etc. the menu for BMW Assist's ”BMW Group Mobile Service” is shown. By
pressing the button, a telephone connection is established with BMW Group Mobile Service. The vehicle
position is transmitted.
Monitoring and loading the accumulators in the Bluetooth handset
The state of charge of the accumulator in the Bluetooth handset (e.g. lithium-ion battery) is monitored
continuously by the Telematic Control Unit (TCU). Whenever the charge level drops below a defined limit, the
TCU switches on the charger in the eject box. [more ...]
Functional sequences
With the Telematic Control Unit (TCU), the following sequential functions are possible:
Hands-free mode with
Full duplex transmission (possible to speak and hear at the same time)
Echo compensation (suppression of background noises)
Display of the operating condition
Transmission of audio data or phone book and telephone status
Monitoring of battery charge state and automatic recharging of the battery in the handset. Control of
voltage supply for the Bluetooth handset. [more ...]
Basic settings
During initial operation, the Bluetooth handset needs to be connected via a connection process to the
Telematic Control Unit (TCU). The first such linkup of the Bluetooth handset to the TCU is done in the
factory. Connecting and disconnecting in accordance with the operating instructions, or with the following
description:
connection of the handset to the TCU.
disconnection of the handset from the TCU. [more ...]
Operation
Handset: The automatic setting up of a radio link with Bluetooth technology can be used to call up the
telephone functions without operating the Bluetooth handset. The convenience functions (lift handset,
phone book entry selection etc.) are available. The functions of the handset are described in the operating
instructions.
Display and operating units: Perform this operation on the actual components installed:
On-board monitor
Multi Information Display (MID)
Multi-Information Radio (MIR)
Central information display (CID)
Radio BMW Professional
Radio BMW Business
Telephone functions: The telephone functions, with the exception of the emergency call, are only enabled
when a SIM card is inserted (Subscriber Identity module). With the Telematic Control Unit (TCU), the
following telephone functions are possible:
Telephone functions
Accept an incoming call
Hands-free mode
Make a call with a handset (privacy mode)
End a call
Transfer the phone book
Emergency call functions
Automatic activation of an emergency call
Manual activation of an emergency call (with the emergency call button)
Breakdown call
[more ...]

Car & Key Memory: ‐‐‐
84 02 03 (010)
ULF universal charging and hands-free facility
E39/E46/E53/E85
Introduction
SA 644 ”universal charger and hands-free unit” ULF is designed for all standard Bluetooth mobile phones. The
ULF forms the interface between Bluetooth mobile phone (hereinafter, where possible, called: mobile phone)
and the components and functions required for telephony in the vehicle. [System overview ...]
The benefits of the universal charger and hands-free kit are:
Using the phone when the vehicle is in motion
With a hands-free system, it is legal to use the phone when the vehicle is in motion. Prerequisite for
phoning with a mobile phone is however a connection to the GSM network (Global System for Mobile
Communication).
Automatic setup of a radio link between the ULF and a mobile phone connected to the ULF.
Phoning without using the mobile phone handset:
Select a phone number from the telephone directory
Make a connection
Accept a phone call
With the ULF, the control functions on the multifunction steering wheel MFL and the various call buttons
can be used.
Monitoring of the state of charge and charging the batteries in the mobile phone.
SA 644 ”universal charger and hands-free unit” ULF does not include
the mobile phone,
the snap-in adapter,
the line compensator (optional).
Procurement of Bluetooth mobile phone handsets and snap-in adapters:
Information about the mobile phones authorised for use in vehicles made by the BMW Group can be
obtained from the BMW Parts Department. Authorised mobile phones can be sourced from the BMW
Parts Department or purchased in any retail outlet.
The appropriate snap-in adapter for any BMW-authorised mobile phone can be obtained from the BMW
Parts Department.
The line compensator (optional) can be obtained from the BMW Parts Department. The installation of a line
compensator improves the use of a mobile phone on the GSM network.
The series introduction of SA 644 and the resultant modifications are listed below:
Model Series End date of SA 632 SA 620 integrated in the SA 620 in conjunction
series introduction SA 644 for telephone with SA 644 also Spanish
SA 644 and navigation and French
SA 620 ”M-ASK language processing system” SVS SA 632 ”Complete preparation for BMW
mobile phone” (Motorola V series)
SA 644 ”universal charger and hands-free unit” ULF
E39 09/02 09/02 (SVS 04/03) 03/03 03/03

E46 09/02 09/02 (SVS 04/03) 03/03 03/03
E53 09/02 09/02 (SVS 04/03) 04/03 04/03
E85 12/02 04/03 04/03

The ULF consists of the following components:
Universal charger and hands-free kit control unit
The ULF control unit contains the components for communication between mobile phone and the
components and functions required for using the phone in the car.
The ULF control unit monitors and also controls the voltage supply for the mobile phone. Whenever
there is undervoltage on the vehicle electrical system, the voltage supply is shut down. [more ...]
Base plate with storage tray
The base plate provides the connection of the mobile phone to the vehicle wiring harness and to the ULF
control unit. The snap-in adapter connects to the base plate. [more ...]
Snap‐in adapter on the base plate:
The snap‐in adapter is the connecting piece between the base plate and the mobile phone. The snap-in
adapter provides the connection to the GSM aerial and to the vehicle electrical system. [more ...]
Bluetooth mobile phone in the snap-in adapter
The back of the mobile phone engaged in the snap-in adapter is connected to the plug connection in the
GSM aerial cable. The mobile phone's battery is supplied with charging voltage via the charging contacts.
The charging voltage is adapted to suit the battery circuitry. [more ...]
Compensator
The compensator (optional) equalises losses in the aerial cable between the snap-in adapter and the
GSM antenna. The line compensator is only required if the operating condition in a mobile phone network
are unfavourable. [more ...]
GSM aerial
The GSM aerial is the transmitter/reception aerial for the mobile phone. The GSM aerial is located outside
the vehicle. With the GSM aerial, communication with the mobile phone network is improved. [more ...]
Bluetooth aerial
The Bluetooth aerial is the transmitter/reception aerial which the ULF control unit uses for communication
with Bluetooth mobile phones. [more ...]
The complete function includes:
Radio
The radio directs the voice information from the ULF control unit as a string of audio frequency signals to
the speakers.
Loudspeakers
The speakers convert these audio frequency signal (AF signals, voice information from the hands-free
module) of the call into sounds then broadcasts these inside the passenger compartment.
Hands-free microphone
The microphone is the input device for voice information to enter the hands-free module. The microphone
converts voice information into audio frequency signals. Due to the hands-free mode function, there is
also no need for operating the mobile phone manually while the vehicle is in motion. Phone numbers can
be selected by voice commands and telephone connections can be established.
System functions
The functions involved in making calls from a Bluetooth mobile phone and the ULF are based on wireless
information transmission with Bluetooth technology. [more ...] The following application options are available
for use:
Functional sequences
Automatic prioritisation of connected mobile phones
Only the most recent mobile phone connected to the ULF is linked up if several telephone calls
arrive at the same time
Hands-free mode with
Full duplex transmission (possible to speak and hear at the same time)
Echo compensation (whistling noise is suppressed)
Display of operating mode
Transmission of data (direct connection from laptop computer to mobile phone)
Automatic monitoring and charging of batteries in the mobile phone [more ...]
Basic settings
Linking up the Bluetooth mobile phone to the ULF
4 mobile phones can simultaneously be linked to the ULF ,
although the mobile phones can be only be used one at a time.
Disconnecting the Bluetooth mobile phone from the ULF [more ...]
Operation Through automatic setting up of the radio link in the vehicle with Bluetooth technology, no manual
control functions are required in normal daily use of the mobile phone. The wireless connection is set up
automatically. The convenience functions (lift handset, phone book selection etc.) are available.
However, a few control actions are required on the snap-in adapter and/or on the display (radio, on-board
computer, etc.) in order to ...
Telephone functions
Accept an incoming call
Conduct a call in hands-free mode
End a call
Transfer the phone book
Change between hands-free mode and privacy mode [more ...]
Car & Key Memory: [more ...]
Non-electrical diagnosis test modules: Important note on non-electrical diagnosis NED
Starting from ISTA version 4.18, the NED test modules in ISTA and NED documents in AIR are no longer available.
Individual scopes of NED are included in ISTA in der electrical diagnosis starting from version 4.18 (under "Current fault
patterns") and in PuMA/SIB.
Going forward, new topics shall be published only via PuMA/SIB.
AM1101_00597 - Engine, noise
Brief description of the test module for non-electrical diagnosis:
Engine noise
Applies to:
Engine: N55, N56
Content (excerpt):
Clicking noise for approx. 10 s after cold start
Increased exhaust noise after the cold start
Rattling noise from the valve gear
Squeaking noise after switching on electrical devices
Hissing noise when pressing the brake pedal after shutting down the engine
Whistling at idle speed
Whirring / rattling from the area of the coolant line from 2000 rpm
Clicking sound after the engine stop
Clattering noise from engine compartment after the wake up of the Digital Motor Electronics
Vehicle communication: Yes

ISTA path:
Activities / Information search / Non-electrical diagnosis / 01 drive / 01 noise / engine noise
Important note:
The fault patterns in the test module depend to some extent on the production period, optional equipment, motorisation
and other features. It is therefore possible that not all content or different content to that described above may be
displayed for different vehicles.
AM1101_00598 - Engine, noise
Engine noise
Applies to:
Engine: N55, N56
Content (excerpt):
Clicking noise for approx. 10 s after cold start
Increased exhaust noise after the cold start
Rattling noise from the valve gear
Squeaking noise from the belt drive
Squeaking noise after switching on electrical devices
Hissing noise when pressing the brake pedal after shutting down the engine
Whistling at idle speed
Whirring / rattling from the area of the coolant line from 2000 rpm
Clicking sound after the engine stop
Clattering noise from engine compartment after the wake up of the Digital Motor Electronics

ISTA path:
Activities / Information search / Non-electrical diagnosis / 01 drive / 01 noise / engine noise
Important note:
AM1104_00187 - Operating fluids leak from engine
Engine operating fluid leak
Applies to:
E46, E83, E87, E90, E91, E92, E93
Engine: M57, M47
Content (excerpt):
Oil loss in the area of the intake port or intake area
Vehicle communication: No
ISTA path:
Activities / Information search / NED / 01 Drivetrain / 04 Operating fluids leakage / Engine leakage
Important note:
AM2301_00285 - Manual gearbox noise
Manual gearbox noise
Applies to:
BMW, MINI
Content (excerpt):
Noise on engagement
Creaking noise when operating the clutch pedal
Noises when starting the engine
Vibrations in the clutch pedal
Noise when the engine is being switched off
Whining when selecting lower gear

ISTA path:
Activities / Information search / NED / 01 Drivetrain / 01 Noise / Manual gearbox noise
Important note:
displayed for differen

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BMW SERIES 3

00 Maintenance and general note 37

Vehicles with low-maintenance battery:

(Change engine oil and oil-filter insert)

Cover alternator with suitable materials.

Release main flow oil-filter cover and remove towards top.Installation:

Remove oil filter element (1) towards top.Installation:

Top up engine oil.

(changing engine oil and oil filter insert)

Cover alternator with suitable materials.

Release main flow oil filter cover and take off.Installation:

Remove oil filter element (1) towards top.Installation:

Fill system with engine oil.

(changing engine oil and oil filter insert)

Withdraw oil-filter element towards top.Installation:

Top up engine oil.

Body / electrical system

Check fluid level in expansion tank; if necessary, top up brake fluid to

For further information on how to proceed, refer to

Change oil with rear axle differential at normal operating temperature.

Unscrew drain plug (2), clean and reinstall.

4.000 cm3 - 2.700 g : 0.86 g/cm³

0.78 cm³/km = 0.78 l/1,000 km

Test certificate for engine oil consumption:

Vehicle data: _____________________________

Added oil quantity (in ccm): _________________ at kilometre reading:__________

Oil consumption [l/1000 km] =

Oil consumption after balancing out: ____________________________ l/1000 km

Visual inspection and leak test

Checking fluid level

Check telltale and warning lamps

Special tools required:

For vehicles with diagnosis socket in engine compartment:

Resetting engine oil service

For vehicles without diagnosis socket in engine compartment:

Checking for leaks:

1 Pump 6 Hollow screw

Checking tyre condition:

Release parking brake New vehicles In general

Check the covers of the interior equipment New vehicles In general

Increase the tyre pressure to 3.5 bar New vehicles In general

Charge battery New vehicles See battery

If possible, keep convertibles in roofed areas New vehicles In general

Scope of checks before driving on the race track:

Check the brake disc thickness on the front axle.

Extensions when driving on a race track:

Scope of checks after driving on the race track:

Perform transfer box oil change.

Wheels / tyres OK Comment

........................................... ........................................... ...........................................

Instructions for removing the protective film:

Car wash and surface inspection:

Procedure in the event of paint swelling:

Protective measures/rules of conduct:

First aid measures:

Safety goggles/face guard

Protective measures/rules of conduct:

First aid measures:

Measures if oil is unintentionally released:

For example: Warning!

Note (symbol for diagnosis system):

Special tools required: Note:

First aid measures:

Added oil quantity (in ccm): _______ at kilometre reading: